Hardware for configuring and delivering power

ABSTRACT

Hardware assemblies, either embedded ( 100 ) or external ( 400 ), which use software ( 101  or  800 ) for processes ( 330  to  356 ) such as acquiring power-related values ( 342 ), principally by the use of a connector ( 132 ) that accesses a battery ( 134 ), in order for a processor ( 102 ) to calculate an optimized power signal ( 338 ), and then to configure an output ( 344 ) of a power supply ( 122 ) to deliver the power signal to a powered device ( 136 ).

This application claims benefit of 60/114,412, filed Dec. 31, 1998.

FIELD OF THE INVENTION

The invention relates to hardware, specifically to such hardwareassemblies that interact with software to configure an optimized powersignal that is delivered to a powered device.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority of “Hardware to Configure Battery andPower Delivery Software,” U.S. Provisional Patent Application No.60/114,412, dated Dec. 31, 1998; and claims benefit of “Systems forConfiguring and Delivering Power, ” International Patent Application No.PCT/US99/31195, dated Dec. 31, 1999; and “Software for Configuring andDelivering Power,” U.S. patent application Ser. No. 09/475,945, datedDec. 31, 1999 (previously filed as “Software to Configure Battery andPower Delivery Hardware,” U.S. Provisional Patent Application No.60/114,398, dated Dec. 31, 1998.) Further benefit is claimed of“Universal Power Supply,” now U.S. Pat. No. 6,459,175, issued Oct. 1,2002, previously filed as U.S. patent application Ser. No. 09/193,790,dated Nov. 17, 1998 (also as International Patent Application No.PCT/US98/24403, dated Nov. 17, 1998, dated Nov. 17, 1998, and issued asSingapore Patent No. 73192, Jun. 11, 2002), filed previously as U.S.Provisional Patent Application No. 60/065,773, dated Nov. 17, 1997;“Power Supply Methods and Configurations,” (a division of “UniversalPower Supply”) filed as U.S. patent application Ser. No. 10/262,380,dated Sep. 30, 2002; and “Method and Apparatus for TransferringElectrical Signals Among Electrical Devices,” now U.S. Pat. No.6,634,896, issued Oct. 21, 2003, previously filed as U.S. patentapplication Ser. No. 09/378,781, dated Aug. 23, 1999 (and asInternational Patent Application No. PCT/US99/19181, dated Aug. 23,1999, withdrawn Oct. 6, 2004) as a CIP of “Apparatus for MonitoringTemperature of a Power Source,” now U.S. Pat. No. 6,152,597 issued Nov.28, 2000, filed previously as U.S. patent application Ser. No.09/105,489, dated Jun. 26, 1998 (and as International Patent ApplicationNo. PCT/US98/12807, filed Jun. 26, 1998), filed previously as U.S.Provisional Patent Application No. 60/051,035, dated Jun. 27, 1997, and“A Resistive Ink-Based Thermistor,” U.S. Provisional Patent ApplicationNo. 60/055,883, dated Aug. 15, 1997, and “Apparatus for a Power and/orData I/O,” U.S. Provisional Patent Application No. 60/097,748, filedAug. 24, 1998. This application further claims the benefit of “Apparatusfor Enabling Multiple Modes of Operation Among a Plurality of Devices,”filed as U.S. patent application No. 09/699,216, dated Oct. 27, 2000, aCIP of “Apparatus for Monitoring Temperature of a Power Source,” ∂aswell as three divisionals of[ “Methods and Apparatus for TransferringElectrical Signals Among Multiple Devices,” Pat. No. 6,634,896, issuedOct. 21, 2003, specifically, “Connector Assembly for Electrical SignalTransfer Among Multiple Devices,” now U.S. Pat. No. 6,866,527, issuedMar. 5, 2005, filed previously as U.S. patent application Ser. No.10/403,253, dated Mar. 31, 2003, “Positionable Inter-Connect Apparatusfor Electrically Coupling Selected Electrical Devices, U.S. patentapplication Ser. No. 10/401,637, dated Mar. 27, 2003, and “InterfaceApparatus for Selectively Connecting Electrical Devices,” U.S. patentapplication Ser. No. 10/402,709, dated Mar. 29, 2003.

SUMMARY OF THE INVENTION

According to the present invention, electronic processor assistedmethods for hardware assemblies and related software to acquire andanalyze information about the power requirements of a powered device,then to configure a power source (which may be embedded, or external) todeliver an optimized power signal to said powered device. These methodsmay be effected, for example, by a processor implementing a sequence ofmachine-readable instructions. These instructions may reside in varioustypes of signal-bearing media. In this respect, another embodiment ofthe present invention concerns a programmed product which includes asignal-bearing medium embodying a program of machine-readableinstructions, executable by a digital processor to perform method stepsto effect battery and power delivery procedures of the presentinvention. The signal-bearing media may include, for example, randomaccess memory (RAM) provided within, or otherwise coupled to, theprocessor.

Alternatively, the instructions may be contained in other signal-bearingmedia, such as one or more magnetic data storage diskettes, directaccess data storage disks (e.g., a conventional hard drive or a RAIDarray), magnetic tape, alterable or non-alterable electronic read-onlymemory (e.g., EEPROM, ROM), flash memory, optical storage devices (e.g.,CD-ROM or WORM), signal-bearing media including transmission media suchas digital, analog, and communication links and wireless, and propagatedsignal media. In an illustrative embodiment, the machine-readableinstructions may constitute lines of compiled “C” language code or “C++”object-oriented code.

OVERVIEW

The hardware and software herein can be represented in a multiplicity ofmodalities, as illustrated in the various figures, and as discussed inthe Description. This Overview is intended to describe the hardware andsoftware in a basic way, in order to better indicate theinter-connectivity and inter-operability of the various major elementsof the invention. Specific details of hardware elements and softwareprocesses are not within the scope of this overview. References tofigures (and their related text in the Description) should be used toprovide more details than are available in this simplified overview.

FIG. 2B depicts an embedded power assembly 100. “Embedded” indicatesthat assembly 100 is permanently located and non-transportable. Anon-limiting example of such an embedded power assembly would be anassembly 100 mounted beneath a passenger seat on a commercial aircraft.Passengers can access a power assembly 100 in order to power variouselectronic devices they bring aboard the aircraft, such as laptopcomputers, personal video viewers, audio players, etc. Power assembly100 provides an accessible power port 103 which, in the aircraftexample, is typically a female receptacle mounted on (or in the vicinityof) the aircraft seat's armrest.

Continuing the example cited, passengers can bring abroad a variety ofpowered devices 136 in FIG. 2, ranging from laptop computers (which canrequire specific input voltages in the range of 12-24 VDC), to personalvideo viewers and hand-held video game players (which can operate atinput voltages from 3-9 volts). Historically, the embedded power unit inan aircraft seat has output a fixed voltage (15 VDC). Passengersaccessing the embedded power unit were required to bring aboard anexternal DC/DC power adapter, which converted the fixed 15-volt sourceat the seat to the correct voltage for a particular powered device.

Embedded power assembly 100 (FIG. 2B) solves the issue of a passengerbeing required to provide a suitable power adapter. Assembly 100 has aconfigurable power supply 122, which can be controlled by MCU 102 tooutput a voltage (in a range from 3-24-volts) compliant with amultiplicity of powered devices 136. Thus, as shown in FIG. 2B, a simpletwo-conductor power cord assembly 115A can be used to deliver power froman embedded power assembly 100, to a variety of powered devices 100. Alow-cost cord 115A can be provided by the airline, in the non-limitingexample cited, thus eliminating the need for a passenger to carry adedicated power adapter for every electronic (or electrical device).

Peculiarities of Powering Devices

Powered devices 136 (FIG. 2B) not only have particular input voltagerequirements, but they also typically require a unique connector attheir power ports 109A. To date, over 40 power connector variants havebeen identified just for laptop computers. Often, similarly dimensionedconnectors (e.g., a variety of connectors generically classified as “5mm barrel connectors,” will mechanically fit powered devices for whichthey were not intended. Both voltage mismatches, and/or reversedpolarity, can result from this power connector inter-changeability.

The invention employs a power connector 132 (FIG. 2B), which attaches toa powered device 136 at its battery pack 134, instead of at thetraditional power-input port 109A found on today's electronic equipment.By attaching to a powered device's battery pack, the number of connectorvariants can be specific to battery connections (see FIGS. 6A, 6F-, 7,and 8). Another benefit achieved by powering a powered device 136through its battery port is that a power assembly 100 can easilyidentify the correct voltage required by a particular powered device.One method of performing a voltage identification is for MCU 102 tosample—on powerlines 114 and 166—the voltage of a battery 134. MCU 102'ssoftware 101 executes a process to acquire, and optimize, what becomesthe output voltage requirement for configurable power supply 122. MCU102 then uses that voltage information, sending a voltage-control signalalong line 130B to configurable power supply 122. Power supply thenoutputs the correct voltage signal on conductors 118 and 120. When MCU102 closes powerline switches 112A, the power signal travels throughconnector 103, then along powerlines 114 and 116, into connector 132.Connector 132 is unique, in that by inserting it in one of its twopositions, it creates an electrical path within battery pack 134 whichbypasses the battery cells. This temporary bypass circuit reroutes theincoming power signal directly to the powered device 136. Powered device136 recognizes the power as being delivered from its battery 134, whilethe actual power source is the embedded power supply 100. When poweradapter assembly 400A is used in place of power cord assembly 115A,powered device 134 gets its power from power box 400.

Placing a power connector interface in a battery pack also allows usersto upgrade their equipment to be compliant with a power assembly 100(FIG. 2B). Batteries, whether rechargeable or primary, are virtuallyalways user removable (or replaceable). Since batteries wear out andneed replacing periodically, users need only replace a worn battery packwith a unit configured with a connector 132. Thus, a battery-based powerconnector is a convenient, and low-cost, way to upgrade almost anypowered device. As discussed above, user costs are further reduced byeliminating the need to purchase the traditional external power adapterrequired to connect to embedded power systems on aircraft (or in anautomobile, as the cigarette-lighter power port). Furthermore, safety isachieved by an embedded power assembly 100 being able to power a device136 with the right voltage. Further safety is achieved by switches 112Achanging the polarity on powerlines 114 and 116 (see FIG. 13A and therelated text for details).

When external power adapter assembly 400A is attached to embedded powersupply 100, the two devices are capable of communicating with eachother. One of the communications methods described herein is powerlinemodulation. This inter-device communication capability allows bothassembly 100 and 400A to interact constructively (see FIG. 13A, andrelated text). The communications link between external adapter assembly400A also extends to communicating with a smart battery 134, so that thesmart battery can communicate data such as the battery manufacturer'sdesign voltage, remaining battery capacity, etc.

Interchangeable Power-Delivery Hardware

Embedded power assembly 100 (FIG. 2B) can power a powered device 136using a simple power cord assembly 115A, comprised of a connector 103,power conductors 114 and 116, and a battery connector 132. But, aspreviously indicated, there are embedded power supplies which output afixed voltage. Non-limiting examples of fixed-voltage power assembliesinclude the aircraft seat units already indicated, as well as afixed-voltage car cigarette-lighter port (SAE spec J1211) indicates adesign voltage for a cigarette lighter port as 9-16 VDC, but the typicalnominal voltage delivered in most cars is in the 11-14 VDC range. Usersof powered devices 1365 which are equipped with a battery pack 134should be able to connect their powered devices to their cars, or toaircraft seats that deliver a fixed 15-volt output.

External power-conversion adapter assembly 400A (FIG. 2B) operates inmost ways just like embedded power assembly 100. Power converter box 400also has an MCU, a configurable power converter, powerline switches, andthis hardware operates with software 800 (detailed drawings of a genericpower box 400 appear as FIG. 13A, and software 800 is illustrated asflowchart 800 in FIGS. 1A-1-1A-9). Power cords 505 and 507 are analogousto power cords 114 and 116 in cord assembly 115A. Connector element 103is interchangeable with that element of cord assembly 115A, so thateither simple power cord assembly 115A, or power adapter assembly 400Acan be connected to an embedded power assembly 100.

External Power Adapter Variants

As with an embedded power assembly 100 (FIG. 2B), so too with externalpower assembly 400A is there an implicit “Universal” power-deliverycapability. One external adapter 400, that is capable of configuring itspower output to match the various voltage input requirements of amultiplicity of powered devices 136, can replace a number of discrete,device-specific power adapters. The Description discusses a number ofways that a single external adapter 400 can replace the various variantsof device-specific adapters commonly available.

Today's electronics goods, whether they be notebook computers, handheldvideo game machines, Personal Digital Assistants (PDAs), tape recorders,or any other type of battery-powered devices, usually ship with an AC/DCadapter. If the user wants to use the devices while traveling in a car,or on a plane, a separate DC/DC power adapter may be either availablefrom the device manufacturer, or can be purchased in the aftermarket.Purchasing such optional external adapters from the manufacturer can becostly, or the manufacturer may not offer such a product (less than 50%of laptops even have an aircraft-style power adapter available at all,and few OEM laptop vendors offer such a product).

In the electronics goods aftermarket, companies like Radio Shack (FortWorth, Tex.), and Targus (Irvine, Calif.), offer power adapters specificto laptop computers, but these are often costly (80-129 U.S.), andexperience has shown that it can take many weeks to get delivery of suchproducts. Once the purchaser disposes (or upgrades to a newer model) ofthe powered device, the power adapter usually cannot be reused, and mustbe discarded. Also, as previously indicated, there is a risk ofconnecting the wrong adapter to a particular powered device. Thisproblem is especially pronounced in larger companies, where a variety oflaptop computer models and brands may be used, and there are poweradapters on hand that look similar to each other, havemechanically-compatible connectors, yet deliver non-compatible voltages.

“Universal” power adapters are available in the marketplace. RadioShack, for example, stocks power adapters with selectable voltage dials,so that a user can manually set an output from as many as six voltages.Other adapter vendors, such as Targus, and Nesco (Van Nuys, Calif.),offer so-called “universal” adapters that require a user to mate aparticular connector tip (or power cord/tip assembly), in order toachieve a particular output voltage. While these devices may offer someslight cost savings over dedicated, device-specific power adapters, theycan hardly be considered universal. Not all connector tips offered byTargus, for example, cover the over 250 models of laptop computers inthe marketplace (Targus claims compatibility with only IBM, Toshiba andCompaq). Both the Targus interchangeable connector tips, and the Nesco“smart” power cords suffer from the already-identified problem of powerconnectors that mechanically are interchangeable among a variety ofnon-voltage-compatible devices, so a user is still faced with theproblem of configuring the power adapter in a way that results in anincorrect voltage being delivered to a particular laptop.

In summary, users are faced with either purchasing costlydevice-specific power adapters, having to deal with knowing enough abouta powered device's voltage requirements to properly turn a dial on amanually-selectable power adapter's dial, or to configure connector tipsor cords in a way that will exactly match the power requirements of aparticular powered device. Power adapter assembly 400A (FIG. 2B) solvesthese problems. Power box 400 automatically configures its outputvoltage, based on power requirements its MCU and software 800 acquirefrom a powered device's battery.

Power box 400 can exist in several variants. A simple power module (seeFIG. 11) connects between a user's fixed-voltage, device-specificexternal adapter and a powered device, in order to confirm that theoutput voltage of the fixed-voltage adapter is compatible with thepowered device requirements. This intermediate module can also assist auser in setting the dial of a multi-voltage selectable power module to acorrect voltage.

In another modality, a manually-selectable voltage adapter can havesufficient hardware and software from a power box 400 (FIG. 2B)incorporated so that a user receives a visual indicator—such as anLED—to indicate that a correct voltage has been matched on avoltage-indicator dial (see FIG. 13-1). The adapter in FIG. 13 alsorepresents a data-enabled external adapter, which is capable of variousdata communications with an embedded power supply, or a powered device.The hardware and software of a power box 400 can even be integrated intoa battery pack, as indicated in FIG. 10, which would result in eitherthe elimination of any external adapters at all, or in a battery packproviding an LED indicator when the correctly matched adapter is in thecircuit.

Thus, an external power-conversion adapter assembly 400A can replace (orenhance the proper operation of) a variety of commonly available poweradapters, with a single “one-size-fits-all” adapter that is used with amultiplicity of powered devices.

As presented herein, software associated with adapter assembly 400Aassumes that every battery-powered device to which the adapter will beconnected is previously unknown and, as such, the software performsvarious acquisition and evaluation operations directed to the device'sbattery each time a device is connected.

LIST OF DRAWING FIGURES

FIGS. 1-1-1-4 illustrate in flowchart form the processes of softwarethat primarily operates with embedded power hardware.

FIG. 1A-1-1A-9 depict a flowchart of the software processes thatprimarily operate with external power hardware.

FIG. 2 is a diagrammatic illustration of an embedded power supply and apowered device.

FIG. 2B is a simplified overview drawing of the major elements whichcomprise both an embedded power supply, and an external power adapter.

FIG. 3A (prior art) shows the elements in a typical microcontroller unit(MCU).

FIG. 3B (prior art) depicts the architecture and port configurations ofa typical microcontroller unit (MCU).

FIGS. 4-1 and 4-2 (prior art) illustrate a schematic of a genericswitching power supply configured to be controllable by amicrocontroller, or other external processor.

FIG. 5 (prior art) shows a schematic of the microcontroller in FIGS. 3Aand 3B, configured to control a switching power supply such as thatshown in FIGS. 4-1 and 4-2.

FIG. 5A (prior art) depicts a circuit which can be added to theschematic in FIG. 5 to provide a means of inducing a load on the inputpowerline of an A/D converter.

FIGS. 6 to 6C illustrate a male connector, and (diagrammatically) itsmating female receptacle with related circuits created when the maleconnector is inserted in two positions.

FIG. 6D shows a detailed view of the male connector in FIGS. 6-6C, witha removable cover that includes a resistive element.

FIGS. 6E to 6F-1 depict a variant of the connector assembly in FIGS.6-6C with two placements of a diode in the circuit.

FIG. 7 illustrates a flexible connector interface that can be installedin battery-powered devices to redirect power to a battery, or to apowered device.

FIG. 8 shows a multi-contact male connector (plug) which can be rotatedto create different electrical paths to a battery, or a powered device.

FIGS. 9A to 9D depict wiring diagrams which either include or exclude a“smart” battery's electronics circuitry in a power delivery path betweena power supply and a powered device.

FIG. 10 illustrates two modalities of an external power-conversionadapter, one being an adapter with a selectable voltage dial, and thesecond being a battery, bath having integrated power hardware andsoftware that is used to power a powered device such as a laptopcomputer.

FIG. 11 shows an external module inserted in the electrical path betweena power-conversion adapter and a powered device's battery pack.

FIG. 12 depicts a simplified function chart of the principles ofoperation of software.

FIGS. 13 and 13-1 illustrate the details of an external power adapterthat has a manually-selectable output voltage, and wired and wirelessdata ports.

FIG. 13A shows a diagrammatic representation of the hardware elements ofexternal power-conversion devices such as those in FIGS. 10, 11, and 13.

FIG. 14 depicts a representational instruction label, with LEDs toprompt a user to perform certain activities relevant to configuringhardware.

FIG. 15 illustrates a look-up table in chart form which associates abattery's minimum and maximum voltages with individual cell voltages andthe number of cells in a battery pack.

FIG. 16 shows a sub-routine of the software in FIGS. 1, and 1A, which isused extensively in various software processes and operations.

FIG. 17 illustrates a chart listing the three positions of a connectorin FIGS. 6-6C.

FIG. 18 depicts a screen display showing power-related information, suchas voltage values, line-load values, connector insertion states, andother data relevant to the operations of hardware and software.

FIG. 19 shows a template created from changes in load during a typicalBIOS POST sequence of a laptop computer.

FIG. 20 illustrates a lookup table used by software in FIGS. 1-1-1-4 andFIGS. 1A-1-1A-9, which correlates line load values to various hardwarestates.

HARDWARE

Note: Matter presented in this section is often also described in othersections, such as in the various software. Any relevant matter isassumed to be included here by reference, as if it were presented herein fill.

Principally, a software program operates on a hardware platformcomprised of a processor, memory (both volatile or non-volatile),controller, and at least one data-acquisition I/O port. A configurablepower supply can be used, but such a device is not essential to theoperation of the software. The elements can be combined as a singledevice (as a non-limiting example, a microcontroller), or as discretesub-assemblies in a multiplicity of combinations. Some or all of theelements can be included in a configurable power supply.

One of the principal functions of the hardware, when used with software101 (FIGS. 1-1-1-4) or software 800 (FIGS. 1A-1-1A-9) is to acquireinformation from a powered device about its power requirements, such asits actual input voltage parameters (and perhaps current-load). Forexample, a device's power-requirement information can be acquired as ananalog voltage signal from a battery pack 134, as is shown in FIG. 2.Battery voltage (and/or current) is converted at MCU 102 in hardwareassembly 100 to a digital data signal. A digital signal is processed, asdescribed in software 101 and 800, and sent as a voltage command toconfigurable power supply 122. Power supply 122 configures its outputvoltage based on information from a processor in MCU 102. Thus, powereddevice 136's correct voltage is properly delivered to it by power supply122, along conductors 114 and 116 in FIG. 2. Assembly 100 in FIG. 2 canalso monitor the electrical load of powered device 136 (see U.S. patentapplication Ser. No. 09/193,790, and International Application No.PCT/US98/24403).

Digital Data

Information about the proper input voltage requirements of a powereddevice 136 (FIG. 2) can also be from data stored in a powered device136. Powered device's memory 104B (volatile or non-volatile) storesinformation, which is retrieved by resident software. Through amultiplicity of available data I/O ports at powered device 136, voltageinformation is delivered to an appropriate I/O port at hardware assembly100 in FIG. 2. Prior art FIGS. 3A and B show a variety of data I/Os atMCU 102. Synchronous, serial, and I²C data links can be created, as anon-limiting example of data I/Os. Should powered device 136 be capableof storing its voltage and load requirements as digital data, that databeing communicated to hardware assembly 100 by a multiplicity ofmethods, including but not limited to, powerline modulation, andwireless infrared.

FIG. 2 shows two conductors 114 and 116 that electrically connecthardware assembly 100 to powered device 136, via associated battery pack134. These two conductors can function as data lines, as well aspowerlines. This would be practical if battery pack 134 is a “smart”battery capable of data communications. Smart batteries, non-limitingexamples of which are those defined in the SMBus specifications(available at www.sbs-forum.org), can be modified to include amodulator/demodulator for powerline modulation. Also, revisions to theSMBus specifications allow for battery and host data available on astandard PCI bus. Conductors 114 and 116 can be used for powerlinemodulation, or additional lines can be added (SMBus is a four-wire databus, and Dallas 1-Wire only requires three).

As shown in FIG. 2, two-wire analog data acquisition is achievable usingpowerline modulation. This shared two-wired power and data topology isviable because power supply 122 is controllable, so it can be shut down,or reconfigured to a compatible voltage with powerline modulation duringperiods of data acquisition.

Alternative Data Acquisition

The 40 programmable I/Os 138, or serial I/O 154, in FIG. 3A can be usedto create a digital data path. As a non-limiting example, 40programmable I/Os 138 can create a parallel port. Serial I/O 154 can be,as another non-limiting example, configured to drive an infrared or RFcircuit for wireless data communications between hardware assembly 100and powered device 136 in FIG. 2. I ²C and SMBus capabilities of theMitsubishi M37515 (which is compliant with I²C data protocols) simplifythe functionality and implementation of this new digital I/O path.Furthermore, the M37515 (or equivalent) can be readily programmed tocommunicate with a “smart battery” 134 in FIG. 2 by usingSMBus-compliant function control unit 144.

Data communications between a powered device 136 (FIG. 2) and hardwareassembly 100 is not restricted to hardwired connectivity. Wireless datacommunications, for example using infrared (134C), RF, or acousticarrays, can be created with appropriate communications devices inhardware assembly 100. Software 101 in FIGS. 1-1-1-4 (and software 800in FIGS. 1A-1-1A-9) are not limited to any particular datacommunications method between powered device 136 and hardware assembly100. For purposes of the processes defined in software 101 and 800, themethod of data acquisition by a hardware assembly 100 from powereddevice 136 or battery pack 134 is not limited to the analog methodsdescribed herein.

Intermediate Hardware

FIG. 2 shows an embodiment of hardware assembly 100, in which MCU 102 isindirectly connected to power supply 122. Intermediate device 126 is acomputer with a display screen (see FIG. 18 for an example of a “PowerMonitor” screen display). Data from MCU 102 is sent to computer/display126 along data lines 130. Computer 126 also controls power supply 122via data lines 124. Computer 126 is not essential to the operation ofthe invention's hardware and software. It serves a useful function inproviding a display for acquired voltage and current-load values, asillustrated in the “Power Monitor” screen in FIG. 18. In someapplications, a graphical user interface and display screen is indicatedas user prompts in software 101 and 800 (FIGS. 1-1-1-4 and FIGS.1A-1-1A-9). This is discussed later under “GUI Considerations.”

Hardware assembly 375 in FIG. 5 eliminates data control lines 124, andrelocates them between MCU 102 and power supply 122, so that MCU 102directly controls the output voltage of power supply 122.

Master Control Unit

An example of an MCU, 102 in FIG. 2 is a Mitsubishi M37515 (FIGS. 3A andB). MCU 102 has a plurality of I/O ports 138, at least one of which isan A/D port. FIG. 2A details three A/D I/O ports 106, 110, and 112. Eachof these is used to acquire powerline voltage (or current), with I/Oport 106 reading voltage under a load condition. The load is provided bya power resistor 108 (or equivalent) in powerline 167. I/O port 110senses voltage as a no-load value at powerlines 114 and 116. I/O port112 detects current at powerlines 113 and 114. Powerlines 107, and 113are all tied to primary conductor 116, which is one of two conductorscomprising cable 115. Additional circuits shown in FIG. 5A can beimplemented at the appropriate I/O ports for current and load-teststates.

The following table identifies the four A/D I/O ports used in software101 (or 800):

Port Drawing Software # I.D. I.D. Function 1 FIG. 2A FIG. 1A Powerlinevoltage acquisition at battery #110 #802 134 or power supply 122'soutput (FIG. 2) 2 FIG. 13A FIG. 1A Powerline voltage acquisition atinput to #518 #809 hardware assembly 100 (FIG. 2) 3 FIG. 2A FIG. 1APowerline load (current) readings #112 #814 4 FIG. 2A FIG. 1A Powerlinevoltage acquisition under #106 #943 supplemental load

Analog signals acquired by I/O ports 106, 110, and 112 in FIG. 2A areconverted to digital signals in A/D converter 140 in FIG. 3A. Asindicated in software 101 and 800 (FIGS. 1-1-1-4 and FIGS. 1A-1-1A-9),some digital data values are stored in memory, either temporarily orpermanently. As appropriate, data values are stored in ROM 148, or RAM146. Processor 150 is used to calculate values, control data flow, timefunctions, etc. Timer construct 142, and/or clock generator 152, can beused for sequencing processes. FIG. 5 illustrates a reference-designtest jig for the Mitsubishi M37515 (a non-limiting example of MCU 102(FIG. 2), as well as MCUs 102A and 102 D (FIG. 13A).

Output I/Os

MCU 102 in FIG. 3A can output a digital signal on a reconfigured I/Oport (not shown, but referenced in FIGS. 3B and 5) created from 40programmable I/Os 138. As a parallel port, not all pins are allocated.MCU 102's programmable I/Os 138 serve to communicate data toconfigurable power supply 122 in FIG. 2. In the modality of configurablepower supply shown in FIGS. 4-1 and 4-2, data input from MCU 102 isexpressed as +0.5 VDC line voltage. Resistor ladder 160 in FIGS. 4-1 and4-2 can be configured in a plurality of output voltage combinations,based on voltage values at pins 2, 4, 6, 8, 10, and 12, which controlthe final output voltage of power supply 122.

Serial I/O port 154 in FIG. 3A can be used for communication outputs,such as control and command functions to the circuitry of a power supply122 in FIGS. 4-1 and 4-2. For example, an LTC1329A-50 from LinearTechnologies (Milpitas, Calif.) can be used (via a serial port) to drivethe LT1339 shown in FIGS. 4-1 and 4-2. The LTC1329A-50 is tied to theLT1339 at pin 12 (Sense) and pin 9 (Vfb). The Linear Technologies'LT1339 requires a modification to perform proper shutdown, as indicatedin the chip's data sheets. Also, Vout is measured at header PIN 20,which is jumpered directly to the positive output terminal block #1 atTB1. To protect against power flowing into the power supply from thebattery, a diode is included in the positive output powerline, but notahead of the jumper that feeds Vout information to PIN 20.

GUI Considerations

FIG. 2 indicates an external processor with a screen display 126.Software 101 and 800 in FIGS. 1-1-1-4 and FIGS. 1A-1-1A-9) use variousscreen prompts to assist the user in manipulating connector 132.Elements of software 101 (or 800) relevant to displaying information(such as the non-limiting examples of Graphical User Interfaces (GuIs)described herein), can reside on appropriate storage media, such asCD-ROMs, DVDs, diskettes, etc., as freestanding software applications,or the software can be “burned” into hardware chips (for example,EPROMS, and EEPROMs) for use with embedded systems which provide adisplay interface. An appropriate display can also be integral withhardware assembly 100, or independent as shown in FIG. 2. A screendisplay can be, as a non-limiting example, an LCD character display (orequivalent), mounted to an enclosure within which resides hardwareassembly 100.

Display screen technologies are not, however, essential to the properoperation of software 101 and 800 (FIGS. 1-1-1-4 and FIGS. 1A-1-1A-9).Other methodologies to guide a user through the simple configurationsteps include, but are not limited to, LEDs that are linked to atext-based information panel or card, as shown in FIG. 14. MCU 102 inFIG. 2 controls status LEDs 420, 422, 424, and 426, using availableprogrammable I/Os 138 to actuate the appropriate LED. Error states,determined by user compliance to a requested action, can be shown byblinking the appropriate LED, for example 420, if a required user actionhas not been performed.

Display screens or LEDs are only two modalities of alerting a user toperform a specific action, or to confirm the appropriateness of theresults of such actions, and are illustrated here as non-limitingexamples only. Any method that will prompt a user is acceptable for theproper operation of software processes defined in software 101 and 800.

Power Supply Modalities

Software 101 and 800 (FIGS. 1-1-1-4 and FIGS. 1A-1-1A-9) is not specificto a particular configurable power supply. A switching power supplydesign 122 in FIGS. 4-1 and 4-2, that configures itself to a correctoutput voltage, is typical of a hardware configuration supported bysoftware 101 and 800. Software 101 and 800 can operate with a pluralityof power supply design modalities.

As a non-limiting example, a power supply which has a method of manuallyadjusting or configuring its output voltage can function according tothe processes defined in software 101 and 800. Instead of the calculatedoutput voltage available from MCU 102 in FIG. 2 being forwarded to aconfigurable power supply 122, the resultant voltage can be displayed ona screen. The user, seeing such voltage information on the screen usesthis data to manually select the matching voltage. Because software 101is capable of verifying that user-selected power supply 122's outputvoltage is correctly matched to the input voltage requirements ofpowered device 136, the user has validation and confirmation of thecorrectness of the selected voltage.

Software 800 in FIGS. 1A-1-1A-9 comprises a method of verifying amanually-set output voltage by using a simple reference-voltagecomparator circuit, or by acquiring and calculating battery outputvoltage. Power supply device 400 in FIGS. 13, 13-1, and 13A includes anLED 402 that is capable of blinking, and also holding a continuous LEDON condition. When Vout and Vout² are the same, LED 402 goes from ablinking state to a continuous ON state. A continuously ON LED 402indicates to a user that an accurate voltage match has occurred. Thiseliminates any mismatched voltage from a power supply 400 which coulddamage a powered device. With this LED confirmation, a power supply 400need not have any voltage values demarcated on manually-adjustablevoltage selector 337. It is not necessary that a user know what theactual voltage values of a selector 337 are, but user only needs to knowthat power supply 400 is in a voltage-matched state, irrespective ofthat actual voltage. Visually defining voltages does, however, offer apsychological advantage, for users who are conversant with voltagematching.

Selector 337 in FIG. 13A uses changes in impedance across its rotatingmanual selector switch to define incremental voltage values. Eachselector setting 416 (FIG. 13-1) has a known resistance value. Theseindividually unique Ohm values are plotted in a look-up table (notshown) that equates an Ohm value to an output voltage value. When thedesired resistive value that equates to a desired output voltage isdetected, LED 402 goes from a blinking state to a continuous ON state.Users cannot mistakenly select a mismatched voltage, which provides ahigh degree of safety to power box 400. Should a user rotate selectordial 504 at any-time after Vout has been executed, MCU 102A ignores theselector.

A Single-LED, Self-Confirming, Manually-Adjustable Power Supply

FIGS. 13, 13-1, and 13A illustrate non-limiting examples of aself-confirming power adapter 335B and 400 respectively that iscomprised of at least one signaling indicator that can be an LED 402.LED 402 is wired so that it blinks during voltage selection, then lightssolid ON when a voltage match is achieved. This indicates to a user thata powered device's voltage, determined by software 800 in FIGS.1A-1-1A-9 is the same as the selected output voltage of adapter 400 atvoltage selector 337. As a safety measure, the tool used to rotateselector indicator 504 is a male “key” connector 404. Connector plug 404in FIG. 13 is shown in FIG. 6D as connector plug 540.

Various modalities of an external power device, such as power adapter335 in FIG. 10, power module 357 in FIG. 11, and adapter 335 B in FIGS.13 and 13-1, are generically illustrated in a block diagram format 400in FIG. 13A MCU 102A has an input 506 (based on 13 selectable outputvoltages) from selector 337. Selector 337 is a rotary switch with fourlines. Each switch position represents a unique binary value that isexpressed on four-conductor-line 506 to MCU 102A. MCU 102A is thus ableto know, by combinations of these binary values, each specific voltagesetting that is selected. MCU 102A interprets these binary values asvoltage selections.

Just as hardware assembly 100 in FIG. 2, power adapter 400 in FIG. 13Ais capable of reading a voltage value from an external powered device508C (item 136 in FIG. 2). Data acquisition at signal lines 523 and 524is configured to read voltage from an external source, such as battery508B. MCU 102A holds power switches 526 and 526A open while reading anexternal voltage from battery 508B. Software 800 (FIGS. 1A-1-1A-9)stores voltage values in MCU 102A's:memory 518A. MCU 102A then looks tobinary inputs from manual voltage selector 337 at data-input line 506.When a user selects a voltage by rotating selector dial 504 that matchesthe voltage value stored in MCU 102A's memory, MCU 102A turns on LED402. This indicates to the user to stop rotation of selector 337 at thatpoint (A discussion of LED variants appears in the “Hardware” section of“Software For In-Line, Corded Power-Delivery Hardware”).

Thus, power adapter 400 (FIG. 13A) can determine the output voltage ofits power converter 122A by acquiring voltage information from anattached battery 508B. Conductors 525, 522A, 519 and 527 provide A/Dconverter inputs to MCU 102A. Line voltage from main powerlines 523 and524 is acquired using A/D lines 525 and 527. Line load values areacquired at conductors 522A (with its resistor 517), and/or conductor519 (with its resistor 521). Further information on how software 101 and800 use these various A/D I/Os to determine the optimum output voltageof a power converter 122A is described in the sections “Conductors andInsulators,” and “Granularity of the A/D.”

An adjusted voltage value, defined by software 800 (FIGS. 1A-1-1A-9) issent form MCU 102A in FIG. 13A to power converter 122A, alongmulti-conductor control line 510. Power converter 122A's resistor ladder(indicated in FIGS. 4-1 and 4-2 as assembly 160) corresponds to binaryvalues expressed by selector 337.

Once power converter 122A has configured its Vout, as commanded by MCU102A, A/D lines 525 and 527 read power converter 122A's Vout. Software800 (FIGS. 1A-1-1A-9) and MCU 102A then apply a resistive load 517 topower converter 122A's output, to test the integrity of the powersettings. If monitored Vout shows negligible voltage sag under load, andhaving confirmed that power supply's Vout matches the desired voltagevalue stored in memory 518A, MCU 102A then closes switches 526 and 526A,allowing power to flow along powerlines 523 and 524 to connector 132,and into battery 508B. The sections “Power Connector,” “ConnectorOperations,” and “Diode UPS” explain how a connector 132 reroutespower-delivery lines within battery 508B to bypass the internal batterycell(s), and deliver power to a powered device 508C.

Power switches 526 and 526 a can be controlled by MCU 102A at controllines 520 to operate as polarity-reversing switches. MCU 102A, alongwith software 800, determines the polarity of the acquired power signalfrom battery 508B using techniques similar to that of a volt meter. Oncethe polarity of the battery on powerlines 523 and 524 is known, MCU 102Aconfigures switch 526 to either close the circuit to powerline 524C, orpowerline 523. Switch 526A can be directed to either powerline 523C, or524.

Data Paths

Power box 400 (FIG. 13A) diagrammatically represents the powered devicesshown as power adapter 335 in FIG. 10, power module integrated into abattery 347 in FIG. 10, power module 357 in FIG. 11, and power adapter335B in FIGS. 13 and 13-1. As discussed elsewhere, each of these powerdevices can communicate with other such devices, with data-enabled“smart” batteries, and even with powered devices such as the laptop 249in FIGS. 10 and 11. FIG. 13A depicts three forms of inter-devicecommunications:

1) Powerline modulation is used between a battery 508B which has aModulator/Demodulator (MD/DM) 508D and a processor such as MCU 102D. Thecorresponding Modulator/Demodulator 508E in power box 400 is controlledby MCU 102A to allow communications along the primary powerlines 523 and524, which are connected to MD/DM 508E with conductors 524A and 523A.MCU 102A uses lines 511A and 511B as data lines to and from MD/DM 508E.A corresponding scheme is employed within battery 508B to configure itsMCU 102D and MD/DM 508D. MCU 102 in power box 400 controls powerswitches 526 and 526A to be open during a powerline modulation session.The power signal on the primary powerlines is from battery 508B,although the powerlines can be configured through switches 526 and 526Ato allow power converter 122A to be the source of power during apowerline session.

In such a configuration in which power is coming from power converter122A, it is advisable to have controllable switches equivalent to 526and 526A in battery 508B's circuitry, so as to isolate the mainpowerlines 524 and 523 during a powerline modulation communicationssession. Such switches would not be necessary if both MD/DMs 508D and508E are capable of modulating a secondary signal across a reasonablywide range of voltages. This type of MD/DM would allow communicationssessions to occur at any time during power information acquisition (abattery 508B's power signal is on the powerlines), or during powerdelivery (power converter 122A is providing the primary line voltage).Since power converter 122A functions within the voltage range ofassociated battery 508B, the two MD/DMs 508D and 508E are likely to beclosely matched in their performance and compatibility within at a givenvoltage range.

Thus, with a smart battery 508B, MCU 102A in power box 400 (FIG. 13A)can acquire data from analog signals (voltage and current) at powerlines523 and 524, or digital data using powerline modulation can be used byMCU 102A to acquire relevant data from battery 508B. Such digital datatypically includes the battery manufacturer's pack “design” voltage, thepresent state of charge (fuel gauge values), and other values onlyavailable by using a true communications link between power box 400 andsmart battery 508B.

2) Data port 406A in power box 400 (FIG. 13A) is used to connect a powerbox 400 to a powered device 508C. FIGS. 13 and 10 depict a power adapterthat has a data I/O port 406, which attaches to a mating data port 406Aon a powered device, shown in a non-limiting example as a laptopcomputer 349. This data link allows a communications-enabled externalpower adapter/module 335 (FIG. 10), 335B (FIGS. 13 and 13-1), or 347(integrated into a battery as in FIG. 10) to access a powered device508C's data storage, memory, and software applications, or even theoperating system to either acquire power-related information from thepowered device, or to share information acquired by the adapter/modulewith the various hardware/software within the powered device. As such,elements of software 101 and 800 (FIGS. 1 and 1A) relevant tointer-device or network communications can be stored on diskettes,CD-ROMs, DVDs, etc., as appropriate for use with powered devices,servers, embedded LAN nodes, and the like. A non-limiting example of ause for this external adapter/module-to-powered-device communicationslink can be to indicate with a screen prompt on the powered device thatselector dial 504 is incorrectly positioned (this assumes that thepowered device is turned ON and operating from battery power).

3) Infrared data I/O 412D (FIG. 13A) is depicted in FIG. 13, asinfrared-compliant upper shell 412 of external power adapter 335B.Infrared emitters 412A and collectors 412B are positioned to allow adiffusely-radiated pattern of light over which data can bebi-directionally communicated. While infrared is shown here as a mode ofwireless communications, RF and acoustic arrays are also viable,depending on the intended function of the data link, and theavailability of compatible devices in the communications environment.Further information about a wireless Ir data link is available in thesection “Modules That Open Closed Data Systems.”

Software flowchart 800 (FIGS. 1A-1-1A-9) does not include detaileddescriptions of the steps in software for a communications session. Thewide variety of communications protocols, and selection of specifichardware, cannot be adequately detailed in a series of communicationssteps in flowchart 800. Since such communications methodologies aspowerline communications, wireless (infrared, RF, etc.), and cabledlinks are so widely known by those skilled in these various arts, therequisite software sequences to read from and write to a communicationsport can be readily implemented. Information on the data protocols for“smart” batteries is available from the Smart Battery Systems (SMBus)web site (www.sbs-forum.org).

Other Data Links

Power box 400 (FIG. 13A) is representative of various hardware found inexternal power adapters and modules such as power adapter 335 in FIG.10, power module integrated into a battery 347 in FIG. 10, power module357 in FIG. 11, and power adapter 335B in FIGS. 13 and 13-1. All ofthese external power units requires a power input from a compatiblepower source. The power source can be either DC, or AC. FIG. 13A depictshardware by which a power box 400 (and related software 800 in FIGS.1A-1-1A-9) can communicate with a power source connected at input powerlines 505 and 507. Such a communications-enabled power source can be,for example, an embedded power module 100 in FIG. 2, which will be usedherein to describe the various communications capabilities.

Just as powerline modulation is used as one of the communications linksbetween power box 400 in FIG. 13A and an attached “smart” battery 508B,so too does power box 400 provide for a powerline communications linkbetween its MCU 102A and a power source 100 in FIG. 2. Note that powersource 100 operates under software 101 (FIGS. 1-1-1-4), while power box400 operates under software 800 (FIGS. 1A-1-1A-9). Power box 400 and itsassociated powerlines and connectors is illustrated as assembly 400A inFIG. 2 for purposes of illustration. Assembly 400 replaces thetwo-conductor cord 115 and its associated connectors 103 and 132, sothat assembly 400 is interposed between a connector 103 of power source100, and a battery pack 134. The sequence of events which occur prior toestablishing a communications link between a power box 400 and powersource 100 are:

1) Pin outs in connector assembly 103 are different for an assembly thanfor the two-conductor power cord shown in FIG. 2. Therefore, whenassembly 400A is attached to power source 100's mating connector 103,power source 100 outputs a default line voltage along powerlines 505 and507 of +5 VDC.

2) Power box 400 (FIG. 13A), as part of assembly 400A in FIG. 2,receives power source 100's 5-volt power signal along conductors 522 and522B, which deliver the power to voltage regulator 505A. The regulatoroutputs a voltage compatible with the power requirements of an MCU 102Aalong continued lines 522 and 522B, to MCU 102A. This voltage activatesand turns ON MCU 102A.

Note: If a user connected a battery 508B to power box 400 (FIG. 13A)prior to making the connection between a power box 400 and a powersource 100, MCU 102 can be turned on with power flowing along lines 523Dand 523E to voltage regulator 505B, with the power then flowing alongconductors 522C and 522D, which are tied into the primary power inputlines 522B and 522 to MCU 102A. If a voltage regulator has sufficientlybroad input voltage range capabilities, a single regulator can replacethe two 505A and 505B.

3) Once MCU 102A is powered by either of the two power sources in step 2above, the MCU uses A/D lines 529 and 528 to sample the voltage on inputpowerlines 505 and 507. Note that MCU 102A closes switch 516, usingcontrol line 515A, to allow power to flow between input powerline 505and line 528. Software 800's steps 801 through 806 (FIGS. 1A-1-1A-9)indicate the software branches related to determining to what type ofinput power source power box 400 is connected. If a 5-volt signal isacquired (software step 803) along lines 529 and 528, power box 400 isconnected to a power source 100 (FIG. 2). If the line voltage is 14-16VDC (software step 804 ), power box 400 is connected to an aircraft'sIn-Seat Power (ISP) outlet, which typically has a voltage of 15-volts(+/−1 volt). If the detected input voltage is in a range of 9-14 volts,MCU 102A in power box 400 assumes that it is connected to an automotivepower source, such as a car cigarette lighter adapter outlet. Thisprocess of identifying a power source is important, because theconnector 103 (FIG. 2) used to attach a power box 400 to a power sourcecan, in some situations, be common to several of the types of powersources indicated.

4) If the voltage on input power lines 505 and 507 proves to be 5 VDC,which distinguishes a power source 100 in FIG. 2, MCU 102A (FIG. 13A)can initiate a powerline modulation communications session.Modulator/demodulator (MD/DM) 528E is accessed by MCU 102A alongsend/receive lines 528A and 528B. The modulated signal then travelsalong lines 528C and 528D, as MCU 102A closes switch 516 via controlline 515A. The MCU can engage or disengage switch 516 to initiate (ordisengage) a modulated powerline communications session. Power source100 also has powerline switches 112A, which are equivalent to switches526 and 526A in FIG. 13A. These switches allow for floating powerlines505 and 507 during a communications session, as well as providing ameans of reversing polarity when a cord assembly 115 is used, instead ofa power box assembly 400A in FIG. 2.

Note that power switch 516A remains open, so that power converter 122Aremains unaffected by a communications session. Power converter 122A isnot capable of operating efficiently from a 5 VDC input, so it is notpractical to keep the power converter 122A in the powerline. Later,power source 100 (FIG. 2) will reconfigure its Vout to 28 volts, at thetime when power converter 122A (FIG. 13A) is about to be configured topower device 508C.

5) Powerline communications continue during the entirety of the softwaresequences defined in flowchart 800 (FIGS. 1A-1-1A-9). Power box 400, andpower source 100 (FIGS. 13A and 2, respectively) communicateinformation, for example, about available alternative communicationshardware in each device. Power source 100 can be a node in a network ofsuch power sources, all linked by a wireless LAN. Power box 400communicates to its networked power source 100 information about anywireless communications link hardware it has. Diagrammatic generic powerbox 400 (FIG. 13A) can, in this non-limiting example, be representativeof an actually external power adapter 335B in FIGS. 13 and 13-1. Poweradapter 335B includes wireless infrared capabilities, so it is importantthat a power source 100 know that there is a wireless link available,since power source 100 also has a compatible Ir port 134C (FIG. 2). Thesecondary Ir communications link enables power box 400 and power source100 to continue to communicate via Ir, after powerlines 505 and 507 havebeen reconfigured to 28 VDC.

Power Delivery

Once MCU 102A in power box 400 (FIG. 13A) has completed its informationgathering from associated battery 508B (which can include acommunications session with a smart battery using powerline modulation,as previously discussed), power box 400 communicates to power source100, requesting a change in powerline voltage from the present 5-volts,to 28-volts. This call can occur via powerline communications, asdescribed.

Should power box 400 not have the requisite hardware for modulating asignal on a powerline, resistor array 509 is used as a simple means tocommunicate the requisite voltage change. MCU 102 (and software 101(FIGS. 1-1-1-4) in power source 100 (FIG. 2) uses its A/D converterfunctions to determine whether or not a power box 400 is requesting avoltage change at its power supply 122. Software 101 describesmonitoring both powerline voltage and current. In particular, software101 is looking for changes to the line load which indicate that MCU 102Ain power box 400 has activated resistor array 509 (FIG. 13A). Theresistive values that resistor array 509 are capable of creating onpowerlines 505 and 507 are pre-determined, and are thus known to bothsoftware 800 and 101. When software 101 detects one of thepre-determined resistive values when checking line load, this serves asa signal for power box 400 to reconfigure the Vout of power supply 122from 5 VDC to 28 VDC.

Software 800, running in power box 400, requests a voltage change insteps 995 and 993. MCU 102A in power box 400 activates resistor array509 along control line 509A. Software 101 in power source 100 (FIG. 2)detects the change in line load caused by resistor array 509, anddirects its MCU 102 to reconfigure the Vout of power supply 122. Since“Input Power” 109 is (in some environments, such as on a commercialaircraft) 28 VDC, MCU 102 closes bypass switch 112B via control line130B. Bypass switch 112B takes power supply 122 out of the electricalcircuit, and allows the 28-volts available from “Input Power” 109 to beconducted along lines 118 and 112, and then to main powerlines 505 and507 in assembly 400A (FIG. 2).

Control line 130C is for MCU 102 to configure the variable Vout of powersupply 122, and is not associated with control line 130B, which isspecific to the control of bypass switch 112B. Lines 120B and 118B arepowerlines along which power supply 122 delivers a compatible powersignal with which to power MCU 102A (this assumes that power supply 122has two outputs, one of which delivers a fixed voltage for powering MCU102, and the other is a controllable and configurable output which iscontrolled by MCU 102.

Software 800 in power box 400 (is steps 995 and 993) detects the inputvoltage change to 28 -volts along MCU 102A's A/D lines 528 and 529 (MCU102A has closed switch 516 in line 528). MCU 102A in power box 400 thencloses switch 516A, which allows the 28-volt power signal to flow intopower converter 122A. Power converter 122A's output is then configuredby MCU 102A to be the optimized voltage previously determined bysoftware 800.

By employing various communications links, power devices can adapt tovarious compatible and non-compatible power sources. Neither softwareflowcharts 800 (FIGS. 1A-1-1A-9), nor 101 (FIGS. 1-1-1-4) definesspecific inter-device communications sessions, because each type of datacommunications—whether it be wireless infrared, or powerlinemodulation—requires specific protocols and hardware interactions (calls,read/writes to various ports, etc.). Since the communicationsmethodologies discussed here are widely known and so readily implementedby those skilled in the art, the description herein of hardwareinteraction, and the non-limiting examples of communications functionscited, are sufficient to allow one skilled in the art to implement thesoftware coding required to create a communications session.

Software 800 (FIGS. 1A-1-1A-9) monitors output voltage and powerlineload during power delivery. If the electrical connection between powerbox 400 and its powered device 508C is ever broken (perhaps by a userremoving connector 132), software 800 shuts down power converter 122A.Further information relating to operation of hardware when configuredwith software 800—such as power box 400 (FIG. 13A)—can be found in thesection “Software Operation.”

Example of a Manually-Configurable Adapter

Because manually-selectable power adapters are so widely available, theadded circuitry in power box 400 (FIG. 13A) to make them safe andreliable is warranted. By modifying a simple manually-selectable poweradapter with the hardware shown in FIG. 13A, the power adapter becomesmuch more universal. It can be attached to any battery-powered devicethrough a connector 132. This lowers the cost of owning multiple voltageadapters, and makes one adapter interchangeable with a number of powereddevices.

Among the various manually-configurable power supplies and adaptersavailable, a product by Nesco (Van Nuys, Calif.) called “SmartAdapter”is a type of manually-configurable power supply. A DC/DC adapter module,which can deliver a range of voltages, is the central hardware device onwhich the SmartAdapter is based. A user selects an appropriate“SmartCord” that matches the input voltage requirements of a powereddevice. Each SmartCord has a specific resistor value that is pre-matchedto an associated powered device. The correct SmartCord is attached tothe SmartAdapter power module to configure a correct output voltage.

But a user must have ready access to SmartCords. Selecting anappropriate SmartCord requires pre-knowledge of power details of theintended powered device, perhaps from users who do not understand theproper reading of product labels that explain input and output voltagerequirements. Also, the sheer number of powered devices suggestshundreds, if not thousands of SmartCords, each dedicated to a specificpower product. These 12″ cords are also easily lost, or confused witheach other.

Power adapter 400 in FIGS. 13 and 13-1 and 13A eliminates the need forinterchangeable SmartCords. Voltage requirements are not determined byusers who may make mistakes, instead a reliable computer processaccurately defines voltage requirements. This adds safety, convenienceand reliability to products like the Nesco SmartAdapter.

Other Power Supply Modalities

“Configurable” power supplies are not limited to auto-configurable, orselector-controlled manually-configurable modalities, as describedabove. User configuration can include a function as simple as choosingthe appropriate power supply from a number available. A corporateManager of Information Systems (MIS) may, for example, need to confirmthat the one of a number of identical-looking power supplies availablein a spares bin is the correct voltage match for a particular powereddevice. Software 800 in FIGS. 1A-1-1A-9 operates to confirm the propervoltage required, and can also, with a hardware module 335 (FIG. 10), or357 in FIG. 11, interface with a pre-manufactured, fixed-output-voltagepower adapter.

A separate module 357 in FIG. 11 can interface between a powereddevice's battery pack and an independent power supply. The function ofthis module is to acquire a battery 355's voltage, using software 800 inFIGS. 1A-1-1A-9, and to compare the acquired voltage information frombattery 355 to configure the fixed-output voltage of a power supply335A. Module 357 cannot use software 800, but can employ a simplehardware voltage comparator. Module 357 can also be a more versatiledata acquisition device that stores at least two voltage values inmemory, each from a different source, and determines if they are amatch. Simple indicators, a non-limiting example of which is abi-colored red/green LED 338 in FIG. 11, are used to indicate whether ornot there is a valid voltage match between an acquired 335A's batteryvoltage and that of a power supply featuring a manually-adjustableselector 337. Only power supply devices that create a valid green LEDindicator when attached to module 357 can be safely attached to apowered device's battery interface.

Pre-Programmed Systems

Automatically-configurable power supplies include embedded or in-linecorded power modules that rely on pre-determined computer-readablevalues-which equate to output voltage matches. A U.S. Pat. No. 5,570,002by Castleman describes a self-configuring power supply system thatrelies on computer chips or other hardware/software. This hardwareessentially pre-identifies an appropriate output voltage of a powereddevice to an embedded, multi-point power supply system. This approach isvery similar to the Nesco SmartCord defined above. But, insteadCastleman relies on manufacturers of powered devices to pre-install achip indicating each device's correct input voltage. Castleman does notaddress the availability of a battery pack interface, but only addressesthe primary power jack or port of a powered device. This limitsCastleman's self-configuring power system to only those powered devicesthat have an embedded chip or other voltage identifier. Furthermore thatchip or voltage identifier software is readable only at a powereddevice's primary power port. Powered devices built before Castleman arenot able to use the multi-point self-configuring power system describedherein.

Software 101 and 800 (FIGS. 1-1-1-4 and FIGS. 1A-1-1A-9) and relatedhardware, provide power device users a battery pack modified asindicated schematically in FIGS. 6-6E. A battery pack modified withconnector system 212 or 212A (FIGS. 6-6E), together with intermediatevoltage-acquisition hardware as in FIGS. 2, 10, 11 and 13, can yield avalid voltage value which can be used by Castleman's power system. Sincebattery packs are usually removable and replaceable,non-Castleman-compliant devices can be upgraded to store a voltage valuerequired by Castleman.

A “smart” battery can communicate its design voltage value as a digitalvalue to a data-enabled intermediate module 357 in FIG. 11.Battery-housing-shaped module 347 in FIG. 10 contains electronicsequivalent to that shown in FIG. 13A (no power converter 122A in FIG.13A is present, since the power converter is in power adapter 335 ofFIG. 10). Modules 357 (FIG. 11) or 347 (FIG. 10) “translate” a voltagevalue, using software 101 or software 800 (FIGS. 1-1-1-4 and FIGS.1A-1-1A-9), to a data signal compliant with Castleman'svoltage-identifier system. Thus, software 101 and 800 (and relatedhardware) enable Castleman's closed-loop system to access voltage valuesat the battery pack interface, instead of the limiting primary powerport of a powered device. The software can also translate analog ordigital voltage-specific information into readable data that iscompliant with Castleman's schema.

Modules That Open Closed Data Systems

Battery-pack-shaped module 347 in FIG. 10 can be comprised of any, orall, of the various elements that comprise hardware assembly 100 in FIG.2. As configured in FIG. 10, the presence of a power converter module335 indicates that a power supply 122 or equivalent in FIG. 2 is notneeded in module 347. However, MCU 102, memory 104B, a controller(considered here as integral to MCU 102 in FIG. 2), and perhaps one ofthe wired (e.g., powerline modulation as Modulator/Demodulator 134B), orwireless communications (e.g., Infrared port 134C) modalities describedherein can be incorporated into a battery-pack module 347 in FIG. 10.Thus, capabilities not already built into a power module 335 can beadded, without modifying the pre-manufactured power module 335. Therecan be, but need not be, a master/slave relationship between the twomodules 347 and 335. This may be true if laptop computer 349 requires asmart battery, but such “smart” battery capabilities are not necessaryto the proper operation of a module 347.

Module 347 (FIG. 10) or 357 (FIG. 11) can be a smart battery emulator,the function of which is to “trick” laptop 349's battery-relatedcircuitry into believing that there is a smart battery present, (insteadof a plastic battery housing full of electronics). Such batteryemulators are available from a number of sources, including David Simm(Bethesda, Md.). Such emulators are used to test smart battery buscommunications hardware and software. If battery charging is to beavoided, the emulator is configured not to request charging activities.Also, since there is no source of power at laptop 349's primary powerport, powered device's internal battery charger will not turn on.

Power adapter 335 in FIG. 10 and 335A in FIG. 11 can be only a basicnon-configurable AC/DC (or DC/DC) power converter. Although both figuresindicate a manual voltage selector 337, in some modalities there may beno ability to communicate with, control, or otherwise configure a poweradapter 335. However, module 347 can confirm the output voltage of poweradapter 335, and allow power to pass through module 347 and into laptop349, only if the input voltage at module 347. matches the powerrequirements of laptop 349. Thus, module 347 serves a vital safetyfunction in protecting laptop 349 from external power adapters like 335that can output a mis-matched voltage.

If a communications link can be established between module 347 and poweradapter 335 in FIG. 10, battery voltage data for powered device349—acquired at module 347—is transferable to laptop 349, viacommunications-enabled power adapter 335. As previously discussed, datacommunications need not be any more sophisticated than powerlinemodulation. A scant amount of data needs to be transferred—only a binaryhex, or other equivalent of a two-digit voltage value, for example. Arobust, high-speed data link is not required.

As shown in FIGS. 13 and 13-1, power adapter 335B has a data port 406.Data connector 406 is shown as a parallel port interface, but it can bea USB, serial or any other data I/O port. This port connector givesaccess for power-related data to software within laptop 349 in FIG. 10.Thus, voltage data acquired at a battery 355 (FIG. 11) by module 357(or, in the alternative, at a battery-pack configured module 347 (FIG.10)) is communicated over powerline 336 (using powerline modulation) toa data enabled power adapter 335. Power adapter 335B (FIGS. 13 and 13-1)has a data port 406 that connects to a powered device 349 (FIG. 10).Voltage data previously discussed as acquired from a battery module 347in FIG. 10 (or external module 357 in FIG. 11) is communicated frommodule 335B, via data connector 406, to powered device 349. Softwareresident on powered device 349 captures voltage data from power adapter335B and stores it in non-volatile memory (or writes it to a storagemedia such as a hard drive). An external module 357 (FIG. 11) can alsohave a data I/O equivalent to a port 406A shown in FIG. 10, and as 406in FIG 13.

Now that powered device 349 has its voltage values in memory, the devicecan communicate that information to any compatible power adapter orother device. This movement of voltage data from a battery to its hostdevice is via an assembly of hardware and software devices which enablenot only compliant power adapters, but also provide power apparatus suchas Castleman's, a way to place data in an accessible location specifiedin his U.S. Pat. No. 5,570,002.

The apparatus in FIGS. 13 and 13-1 is also capable of communicating datawirelessly. Top shell 412 of power adapter 335B is fabricated oftranslucent plastic, tinted to be compatible with infrared light. Belowthe tinted Ir cover is a matrix of infrared LEDs (emitters) 412A andcollectors 412B, typical of “diffuse” (i.e., non-directional) infrared.The emitters and collectors are arranged so as to disseminate lightalong various 30×120-degree paths. Collectors are physically isolatedfrom emitters by partitions 412C, so that the collectors are not“blinded” by the emitters. The number of emitters and collectors canvary, according to the requirements of various diffuse infrared vendors.IBM (Markham, Ontario, Canada), Siemens (Bonn, Germany), and Spectrix(Mundelein, Ill.) are companies which have developed diffuse infraredtechnologies which do not require a specific “point-to-point” alignmentof infrared beams.

By using diffuse Ir, the entire top surface, and some portion of thesides of the top shell 412, of power adapter 335B disseminate infraredlight into the local environment where, as a non-limiting example, thedata within the non-collimated light beams can be captured by a hostdevice 349 (FIG. 10). This wireless capability eliminates the need for adata I/O connector 406 on power adapter 335B in FIG. 13, allowing thedevice to positioned anywhere in proximity (typically diffuse infraredoperates within a range of 10 meters) to its powered device.

Such diffuse infrared capabilities also enable a number of poweradapters 335B (FIG. 13) to be wirelessly linked to a compatible localarea network. A non-limiting example of such a LAN can be an aircraftcabin configured with diffuse Ir receptors (transceivers) that transmitand receive data over the infrared network, so that power adapters suchas 335B can communicate power-related activities at each node on the LANto a server. The server thereby can monitor overall power consumption inthe environment, report on the possible misuse of any power adapter335Bs by airline passengers, report on a failing module that requires aservice call—or to monitor the amount of time an adapter is used, sothat an airline can charge a passenger for power usage. Thus, such awirelessly networked power grid of power adapters empowers a number ofpractical solutions which benefit users and providers of power equipmentsuch as power adapter 335B (or equivalents).

Software Access Adds Safety

By making powered device's voltage requirements available at thedevice's software layer, certain safety benefits are achieved. Smartbattery topologies treat battery communications as a closed system. Notonly are software applications resident on a powered device unable toaccess smart battery bus communications, but even the operating systemhas firewalls between it and the battery data bus. Until recently, thisclosed system approach made sense. Smart battery technology brought areasonable level of safety to charging highly-volatile Lithium-Ion(Li-Ion) battery cells. But, commercial airlines are now adverse to eventhe slight risk that an onboard laptop could. cause a dangeroussituation by charging its battery while in flight. The inviolate closedbattery bus now needs outside intervention, so that battery chargingactivities within laptops can be temporarily disrupted during flight,but resumed when those laptops are on the ground.

A system that allows smart battery bus data to be transferredbi-directionally to/from a powered device's application or operatingsystem levels can be created using elements described in the section“Modules That Open Closed Data Systems.” Such a data system has abattery pack interface. Male connector 290 in FIG. 8 provides sufficientdata lines 292, 294, 296, 298, and 299 to redirect all battery buscommunications to an external system. These five conductors of aconnector 290 can be directed to a hardware assembly 100 in FIG. 2. IfMCU 102 is a Mitsubishi M37515, the I²C/SMBus data port can provide acompatible I/O for the smart battery bus data. Microcontroller 102 iscapable of translating the I²C data protocol to RS 232 data, which canbe output at an I/O port. This data port can be the existing serial port154 in FIG. 3A, as a non-limiting example, or a created parallel portconstructed from the 40 programmable I/Os 138. The above description isnot limiting to those particular elements referenced here by example,but can be any combination of elements that perform equivalent functionsto create the system so described.

Software 101, and 800 (FIGS. 1-1 —1-4 and FIGS 1A-1 —1A-9 respectively)can be integrated into an MCU, or equivalent processor or controllerchips. Since elements of both software 101 and 800 relate to functionsor operations not necessarily specific to software embedded into a chip,or processor, some software routines or sub-routines discussed hereincan be distributed on media such as diskettes, flash, ROM (CD or DVD,for example), or equivalents. This distributed software can be anapplication purchased by an end user, and loaded onto a powered devicesuch as a laptop computer, for non-limiting features such as a “PowerMonitor” display.

Data port 406 in FIG. 13 provides power adapter 335B a means ofsending/receiving data acquired from a smart battery bus, as describedabove, and transferring such data to software running on a powereddevice, such as a laptop. Linking these various elements togetherprovides a data loop that starts at the otherwise closed smart batterybus in a powered device, rerouted through an external device, then intoan available data port on the powered device. Software on the powereddevice can thereby monitor battery bus activity. If charging occurs, forexample, monitoring software 101 (FIGS. 1-1 —1-4) or 800 (FIGS. 1A-1—1A-9) can send a command to the data-enabled external power adapter toshut down.

Smart Battery Bus Extensions

The closed bus topology and architecture typical of smart batterysystems is evolving into a more open platform. SMBus specificationsinclude smart battery bus “extensions” that, to a limited degree, allowother hardware sub-systems in a powered device access to apreviously-closed data bus. Extensions to the PCI bus allow the CPU,BIOS and other devices to have limited input and outputs on the smartbattery bus.

In the evolving specifications, external devices such as power adapters,can potentially access battery and charger data. While no provisionscurrently exist for an external device to manipulate a powered device349's charger control, a power adapter 335, 335A, or 335B (FIGS. 10, 11,13 respectively) (and schematically 400 in FIG. 13A) is capable ofmonitoring battery and charger activities. One means of controllingcharging from an external device 335 is by disabling power to a powereddevice (assuming that an external adapter is delivering power to adevice's primary power port 343 (FIGS. 10 and 11), instead of utilizingthe battery bypass shown in FIGS. 6-6E). Although an aggressiveapproach, discontinuing external power delivery can be rendered aharmless event. An external device such as module 335A (FIG. 11) thatcan monitor a battery data bus to confirm that a battery pack 355 hassufficient remaining capacity to power its host device. This eliminatesany risk of a possible hardware crash caused by lack of battery powerwhen shutting down external power in order to prevent battery charging.

Thus the various power adapters 335 or equivalents shown in FIGS. 10,11, 13, 13-1, and 13A are enhanced by data port 406 in FIG. 13. Asspecifications for smart battery bus extensions open up powered devices'parallel, serial, PC Card, USB and infrared data ports, power adapterssuch as the variants of 335 are capable of participating in buscommunications.

Data Available to Other Systems

As a non-limiting example of the applicability of the bi-directionaldata system described above, it can serve as a precursor to the powerapparatus described by Castleman. Castleman describes an embedded powerand data bus, but does not allow for data access to a battery port. Byfirst transferring—by powerline modulation—the power information(consisting of the voltage and current values required by Castleman)from a battery pack to an external device such as a power adapter (335Bin FIG. 13); then, secondly, transmitting the power information nowcaptive in the power adapter to its available data port (connector 406,or infrared port 412) where, finally, the power information is nowstored in the powered device's ROM, RAM, or written to a storage medium.Thus, the power information which originated at a battery, has now beentransferred to the battery's associated powered device. The powerinformation is stored within the powered device until the powered deviceis attached to the Castleman apparatus. One of Castleman's data cablescan then extract the stored power information from the powered device,and use it to configure the output of their embedded power system.

Castleman can also access the battery port via a connector 290 in FIG.8, for example, used in conjunction with a module 347 in FIG. 10. Module347 is needed because Castleman addresses common data ports, and notports that support SMBus (or Dallas 1-Wire) data protocols. Therefore,module 347 is needed to translate smart battery bus data to a formatreadable by Castleman's apparatus. Furthermore, since software 800 inFIGS. 1A-1 —1A-9 is already resident either on a powered device (eitherembedded in a powered adapter 335 in FIG 10, or an in-line module 357 asin FIG. 11), a Castleman-compliant cord with an embedded Dallas chip canbe connected, and the chip can be written-to from a modified version ofsoftware 800. Thereafter, the cord can be used according to Castleman'sapparatus. The Dallas Semiconductor “I-Button” series of writeable datachips can be written-to using a 0.5-volt power signal at a parallelport, as a method of creating a Castleman-readable chip.

Even with this power-requirements data now available to the Castlemanapparatus other required parameters that identify device classes andtypes cannot be properly generated. Thus, concerns raised by Castlemanabout powered devices that radiate EMI can only be ascertained by suchdevices' manufacturers. No data about such device characteristics arestored, nor can that information be generated by a device that has leftthe manufacturing process without having had that information embeddedspecifically for Castleman.

Castleman Cords

The above-described data transfer techniques, with an added means ofwriting to a Dallas (or equivalent) chip embedded in a cord connector,enables the assembly of hardware and software thus created to generate“Smart Cords” on the fly. Any powered device which can be accessed atits battery, whether that battery is “dumb” or “smart,” can providevalid voltage information. This voltage information can be captured bysoftware resident at various locations throughout the system, such as ina processor-enabled adapter or module, or in the powered device itself.

Information on current requirements, while not essential, can also begathered at a battery report by placing the battery under a known loadfor a defined amount of time. Because battery charging has beendisabled, the load caused by the battery charging process, which cantypically be 20 Watts or more, is no longer an issue, so even previouslymarginal power adapters and embedded power systems have a power reserve.

Whether the values required in a “smart chip” or “smart cord” arespecific to voltage and/or current, such data can be written to a cordwith an embedded chip (ROM, EPROM, EEPROM, FLASH, etc.) by using thehardware and software described herein.

An Extra Bit of Safety

The modality of power adapter 335B with a connector port 406 as shown inFIG. 13 (or an equivalent), also gains an additional safety feature.Adapter cords, especially when used on an airplane, can becomedisconnected from the powered device. This can occur simply by theweight of the adapter, dangling from a passenger seat's food servicetray causes a connector to become disconnected. That problem is resolvedby attaching data connector 406, or an equivalent, to a powered device,as shown in FIG. 10. This arrangement makes for a clean implementationwithout dangling cords, and has the adapter firmly anchored to itspowered device. This arrangement also minimizes cord fatigue, thusextending the life of the power adapter assembly.

Closed-Loop Data Acquisition

The processes defined in software 101 and 800, FIGS. 1-1 —1-4 andFIGS.1A-1 —1A-9 respectively, includes methods of acquiring battery packvoltage without the inclusion of a specific type of power supply. FIG.11 shows an intermediate data acquisition module 357 to which aplurality of power supply types and battery packs can be connected. Thismodule is not restricted to the form-factor of an in-line device. It canbe expressed, as a non-limiting example, as a PC Card (previously PCMCIAcard). It can be a module that communicates with a powered device byattaching to a data port, or that wirelessly sends voltage and otherinformation from software 101 or 800 in FIGS. 1-1 —1-4 and FIGS. 1A-1—1A-9 to a powered device. Thus, software 101 and 800 can operatewithout a power supply as an interposed communicatins element, per se,by using a module 357 to acquire data at a battery, then to convey it toa powered device through any available data port, so as to render suchdata accessible to software.

The commonality of the hardware assemblies in FIGS. 10, 11, 13, andschematically 13A is that they are all closed-loop systems. A powereddevice accesses its own battery via an external module in order toidentify the power device's electrical characteristics, in particularvoltage (and perhaps load current). Once acquired, this power-relateddata can be stored in a powered device's internal memory, written to ahard drive, or otherwise logged in an accessible location. By placingbattery information at the application level within a powered device,for example a laptop, this data can be accessed by a plurality ofpower-specific devices. For example, software that relates to powermanagement can, when assisted by a hardware assembly 400 in FIG. 13A,monitor battery capacity by updating changes in voltage (and/or)real-time current loads that are indicators of remaining capacity. Thus,by using a closed-loop hardware assembly and software 101, or 800 (inFIGS. 1-1—1-4 and FIGS. 1A-1—1A-9, respectively), powered devices thatare not powered by “smart” batteries can operate more efficiently andsafely. Thus, certain missing “smart” battery capabilities are createdin on-board software and data connectivity from attached,communications-enabled hardware assemblies.

Adapter Voltages Don't Match Battery Pack Voltages

Users of powered devices have specific needs for battery informationthat are addressed by one or more of the modalities of software 101 and800 in FIGS. 1-1—1-4 and FIGS. 1A-1—1A-9. Non-limiting examples of theseneeds have already been defined as not charging batteries on aircraft,or to access an embedded power system by creating a “smart cord.” Usersare connecting an external power system to a powered device at itsbattery I/O, and not to the usual power input port. A powered device'sbattery port typically does not accept the same voltage as would thepower adapter input jack located elsewhere on the powered device. Apowered device that operates on a 12 VDC battery will typically requirea higher voltage at its external power port. This is usually dictated bythe need to charge the battery pack from a power source that delivers ahigher voltage than the battery, itself.

Assuming that the user is relying on fixed-voltage adapters, thistwo-voltage model creates a need to differentiate external DC adapters,since connecting a 12-volt adapter (that matches a battery pack'svoltage) to the external power port on a host device may likely delivera voltage that is insufficient to properly power a device. Voltageacquisition and verification available from software 101 and 800 inFIGS. 1-1—1-4 and FIGS. 1A-1—1A-9 allow a user to compare a voltagedisplayed on a screen (or otherwise readily identified) to thatindicated on an adapter. This brings a layer of safety to the operationof any powered device, by eliminating guesswork that could result inconnecting a voltage-mismatched adapter. Any of the hardware assembliesshown in various figures herein will correctly identify a powereddevice's voltage, when used with software 101 and 800 in FIGS. 1-1—1-4and FIGS. 1A-1—1A-9. Furthermore, that same software and hardware canverify that an adapter is the correct one for that powered device.

Power Connector

A power connector 132 shown in block diagram FIG. 2, used with software101 and 800 in FIGS. 1-1—1-4 and FIGS. 1A-1—1A-9, has specificconductive and insulator characteristics which enable the correctsoftware processes. A connector 132 operates by isolating the cellswithin a battery pack 134. A detailed view of male connector is shown inFIGS. 6A and 6D. As shown in FIGS. 6-6C, battery cells 182 areelectro-mechanically separated from battery housing's exposed contacts174 and 175 at power interface 194. The internal wiring of battery pack134 has been reconfigured to include a connector interface comprised ofcontacts 176, 178, and 180. Normally, conductive lead 188 from cell(s)182 only connects to exposed contact 174. Positive lead 188 has beenrewired with a “T”-connection 190, creating new conductor 188A, whichterminates in spring contact 180.

Conductive lead 184 from battery cell(s) 182 in FIG. 6 originally waswired directly to exposed contact 175. As modified, power lead 184 nowterminates in spring contact element 176. An opposing spring contactelement 178 continues the power circuit along conductor 186 to contact175. Even though the internal wiring of battery pack 134 has beenmodified, the battery pack operates normally when a male connector 132is not present. Spring contacts 176 and 178 are normally closed, so thatpower from cell(s) 182 can flow directly to contacts 174 and 175 as ifthe internal wiring had not been modified, as shown in FIG. 6.

Connector Operations

Software 101 and 800 in FIGS. 1-1—1-4 and FIGS. 1A-1—1A-9 operatesaccording to the various positions of connector 132 in FIGS. 6-6C. Byreferencing FIG. 6A to establish the conductive and insulator of maleplug 132, the first position of inserted male plug 132 into the matingcontacts 176, 178, and 180 within battery pack 134 is indicated in FIG.6B. The conductive path created by the insertion of male plug 132 flowsfrom battery cell(s) 182 along the first conductor 184, to springcontact 176, where the electrical signal is transferred to male plug132's conductor 202 (as shown in FIG. 6A) then on to an external powersource.

From battery cell(s) 182, a second electrical path is along conductor188, then continuing along conductor 18A, where the electrical signal istransferred to male plug 132's conductor 206 (see FIG. 6A), then on toan external power source.

The direction of electrical flow along the paths described above is fromthe battery cell(s) 182 to the external power source. This allowssoftware 101 and 800 (FIGS. 1-1—1-4 and FIGS.1A-1—1A-9) in the externalpower source (or a separate device) to acquire power-relatedinformation, such as a voltage of battery cell(s) 182. Software 101 and800 use both a Vmin voltage (under load), and a Vmax (no load). Asuitable resistive load is applied in the external power supply to allowa Vmin voltage reading. If current readings are required, this resistiveload is also used. (See resistive elements 108 and 108A in FIGS. 2 and2A, and the related text in the Description for further information onthe resistive load and related wiring. In particular, FIG. 13A usesresistive elements 517 and 521, as discussed in the section “Vmin”).

Software 100 and 800 (FIGS. 1-1—1-4 and FIGS. 1A-1—1A-9 respectively)use the acquired information on voltage (and current if indicated) toconfigure an external power supply—for example, the representationalpower supply 122 in block diagram FIG. 2. The software processes aredefined in “Software to Configure Battery and Power Delivery Hardware.”

Once power supply 122 in FIG. 2 has been configured to a voltage thatcorrelates to that of battery cell(s) 182 in FIG. 6B, connector 132 mustbe repositioned. A user is instructed to remove connector 132. frombattery pack 134, and to axially rotate it. This rotation switches theposition of conductor 202 and insulator 208 (see FIG. 6A), so theconductor and insulator are now the obverse of their original positions.

FIG. 6C shows male connector 132 in a second position. Power signal froma power source flows along conductor 202 (FIG. 6A) in male connector132. Conductor 202 in connector 132 (FIG. 6C) is now electrically incontact with spring contact 178, so that power from the external powersource 122 now continues along powerline 186 to contact 175 on batterypack enclosure's connector 194.

A power signal from the power source in FIG. 6C flows along conductor206 in male connector 132 (FIG. 6A) which is now electrically in contactwith spring contact 180, so that power from the external power sourcecan now flow along powerline 188A to interconnected powerline 192, thento contact 174 on battery pack enclosure's connector 194. When batterypack connector 194 is mated to connector 196 of “system” (i.e., powereddevice 136 ), a power signal from the power source flows into powereddevice 136.

Note that in this second position of a male connector 132, becauseinsulator 208 in FIG. 6A electrically isolates battery cell(s), no powercan flow from battery cell(s) 182, even though the positive (+) side ofthe cell(s) is still in the newly-created circuit 212B in FIG. 6C.Battery cells 182 are neutralized from being charged, by beingeffectively removed from the circuit between the power source andpowered device 136 in FIG. 6C. Essentially, a Y-connector has beencreated, the base of which is comprised of spring contacts 176 and 178.The two branches of this Y-connector—one of which leads to batterycell(s) 182, and the other branch to powered device 136—are selectableby positioning the conductive side 202 of a male connector 132 to beelectrically attached to one branch or the other.

Note that the ground (−) powerline, as is shown in FIGS. 6-6C, is notalways disrupted. FIGS. 9A-9C show either disrupted positive or groundlines. Each battery pack is addressed on a case by-case basis indetermining which powerline to wire to spring contact clips. Software101 and 800 (FIGS. 1-1—1-4 and FIGS. 1A-1—1A-9) include reverse polaritydetection and correction. Since the first position of a male connector132 causes power to flow from a battery 182, the determination ofpolarity is obvious to anyone skilled in the art.

Safely Disabling the Battery

One of the safety functions male connector 132 in FIGS. 6-6E achieves ispreventing battery charging. By electro-mechanically isolating the cellswithin a battery pack, battery charging is efficiently prevented. It mayseem that the same function could be achieved with a totallynon-conductive male connector 132 inserted into a battery pack circuitsuch as that shown in FIGS. 6-6C. With such a filly-insulated connectorinserted, power could be delivered to the primary power port of apowered device, yet the battery pack would not charge.

While this fully-insulated male connector approach would certainlyelectro-mechanically prevent battery cells from charging, the powersignal at the primary power port of a powered device can still turn onthe powered device's internal charger, and potentially damage circuits.Also, a number of powered devices, especially laptop computers, have abattery pack that is wired in series with the primary system circuits.The battery pack must not only be present, but operational (often areference-voltage circuit is employed) for the powered device tofunction. Thus, it is neither desirable, nor prudent, to power a deviceat its primary power port, while disrupting the battery pack's internalcircuit. It is much more reliable and safe to power a device through itsbattery pack.

Furthermore, with the widespread use of “smart” batteries, powereddevices are sometimes designed to execute a data handshake with abattery pack during system boot/initialization. If no batteryacknowledgment occurs on the battery-system data bus, a host system maynot operate. When powered from an external wall adapter, for example,some laptop computers will not is operate because the system cannotlocate a battery device.

A laptop's battery is not only a secondary power source when no externalpower is available, but the battery serves an important UninterruptablePower Supply (UPS) function. Should external power be lost (e.g., theexternal AC/DC adapter is inadvertently unplugged from the wall), datacould be lost. Therefore, it is essential that the battery always beinstalled and available to act as a UPS. When connector 132 in FIGS.6-6C is removed, battery 182 immediately continues powering its hostsystem. Spring contacts 176 and 178 instantly close, restoring acomplete power circuit between cells 182 and connector 194 alongconductive paths that are readily identified by those skilled in theart.

Diode UPS

FIG. 6E depicts a connector assembly and related wiring 212E, which isanother modality of such a connector assembly depicted in FIGS. 6, 6A,6B, and 6C. The addition of a diode 185 in the circuit between opposingspring-loaded contact beams 176 and 178 allows a power signal frombattery cell(s) 182 to flow along conductor 184, through diode 185 toconductor 186. The power signal now available on conductor 186 isaccessible at contact 175, making power available from battery 182 to apowered device's system 136. Thus, even though an inserted maleconnector 132 has temporarily disrupted the flow of the battery 182'spower signal across contact beams 176 and 178, diode 185 provides analternative path for power. Should power from an external power sourcebe disrupted that was flowing through male connector 132 to contact beam178, then along conductor 186, to contact 175, diode 185 creates a newconductive path, so that battery 182 can take over powering powereddevice's system 136. (See the description relevant to male connector 132in FIG. 6A for details on how the connector assembly operates).

Thus, power from battery 182 is available to its associated powereddevice 136 any time that voltage along conductor 186 drops below thebattery cell(s) 182's voltage. Should external power be disrupted, diode185 provides an effective Uninterruptable Power Supply (UPS) function,even though connector 132 is still inserted in battery housing 134. Thisfunction also applies should connector 132 be partially disconnectedduring power-delivery operations—if male connector 132 were fullywithdrawn from mating female connector assembly 179, spring-loadedconductive beams 176 and 178 would close to provide an electrical pathbetween battery 182 and powered device 136.

Diode 185 in FIG. 6E also provides a path for a battery 182's powersignal at spring-contact 178. In the description elsewhere of theoperation of a male connector 132, the male connector 132 is required tooperate in a two-position mode. FIG. 6B depicts a Position #1 of a maleconnector 132. In this position, an electrical path is created between abattery cell(s) 182 and an external power source along conductor 184, tospring-loaded conductive beam 176, then through connector 132 along itselectrical contact 202 (see FIG. 6A). This electrical path created bythe insertion of a male connector 132 in its Position #1 allowed anexternal power source (such as a power conversion adapter 400diagrammatically shown in FIG. 13A) to acquire voltage readings frombattery 182. The positioning of diode 185 does not allow a power signalto flow from conductor 186 into battery cell(s) 182.

By the addition of diode 185, and the new electrical path created frombattery 182 to conductive beam contact 178, the need to insert a maleconnector 132 into a Position #1 is eliminated. Instead, male connector132 as inserted in FIG. 6E, can acquire battery cell voltage atconductive beam 178, since the conductive element 202 of male connector132 is now in contact with conductive beam contact 178, instead ofconductive beam contact 176 (see FIG. 6C for male connector 132'sPosition #2 ). Thus, a power signal from battery cell(s) 182 flows alongconductor 184, then through diode 185, to conductor 186, where the powersignal is available at conductive beam contact 178. The power signalthen is transferred to conductor 202 in male connector 132, which is inelectrical contact with beam contact 178, and the power signal is nowavailable to an external power source. Thus, diode 185 eliminates of theneed to insert a male connector 132 in a Position #1. Instead, a singleinsertion into what was previously male connector 132's Position #2 isnow all that is required.

It may appear as if there would be contention along power conductor 186when an external power source is delivering power through a maleconnector 132 (FIG. 6C shows the Position #2 power-delivery orientationof male connector 132). Since, in FIG. 6E, battery cell(s) 182 candeliver a power signal to conductor 186 through diode 185, and anexternal power source is also simultaneously applying a power signal toconductor 186 through conductive beam 178, a state of contention appearsto exist. This is resolved by the external power source's relatedsoftware (software 101 in FIGS. 1-1—1-4, or software 800 in FIGS.1A-1—1A-9) configuring the Vout to be of a higher value than can bedelivered by battery 182 through diode 185. The voltage depressioncreated by diode 185 works in favor of allowing an external powersource's Vout to be the dominant voltage on conductor 186.

Note that a “bleed resistor” 185A is available that shunts across diode185. This resistor is not essential to the operation of the invention.It allows a non-depressed voltage value to be available to an externalpower source. Without such a bleed resistor, software 101 (FIGS.1-1—1-4), or 800 (FIGS. 1A-1—1A-9) in an external power source wouldcompensate for the depressed voltage value caused by a diode 185 in theline. Such a resistor arrangement should be approached with caution,since it does create a potential bypass path around diode 185. Thoseskilled in the art will be able to properly implement such a resistor inthe circuits shown, but the implementation of a diode 185 without anresistor 185A is certainly appropriate in most circumstances.

Diode 185 in FIG. 6E becomes electrically transparent to the batterycircuit in battery pack 134, once male connector 132 is removed (seeFIG. 6). A battery power signal flows through conductive beams 176 and178, essentially bypassing the strapped diode 185 (diode 185 will onlybe fully bypassed if there is a proper implementation of a bleedresistor 185A, so that the power signal does not flow through resistiveelement 185A).

The location of a diode 185 is not limited to that shown in FIG. 6E. Analternative location is shown in the detail of a male connector 132A inFIG. 6F-1, which differs from the male connector 132 shown in FIG. 6E.Male 132A has conductive elements 202 and 202A above and below a centralconductor 206, each separated from the other conductors by thininsulators 204 and 204A. Conductive element 202 does not pass throughconnector backshell 210, but instead terminates inside backshell 210.Diode 185B is strapped across conductive elements 202 and 202A, so thatthe direction of power signal flow is from upper conductor 202, downwardto conductive element 202A.

When a male connector 132A (FIG. 6F-1) is inserted into mating connectorassembly 179 (FIG. 6F) in a battery pack 134, conductive beam 176 iselectrically active to male connector element 202, and opposing femaleconductive beam 178 is electrically attached to male connector element202A. The battery power signal can flow from cell(s) 182 along conductor184, to conductive beam 176, where it transfers to male connectorelement 202, then travels through diode 185B, and along conductiveelement 202A out to an external power source. This provides the voltageacquisition modes called out in software 101 (FIGS. 1-1—1-4) and 800(FIGS. 1A-1—1A-9).

When the external power source applies a voltage signal (Vout) to maleconnector 132A (FIG. 6F), the power signal travels along conductiveelement 202A, but is prohibited from traveling into conductive element202 by diode 185B (FIG. 6F-1). Therefore, the power signal travels tothe terminus of conductive element 202A, where it is electricallyattached to conductive beam 178 in female connector assembly 179. Thenpower signal then passes along conductor 186 in battery pack 134,reaching contact 175, where the power signal can then be transferred tothe power device's system 136 at a mating contact and conductor 200(connector 196 and its conductors 200 and 198 are internal to powereddevice 136, as would be the case with battery contacts in a removablebattery's bay, for example). As noted previously, the Vout voltage froman external power source must be of a higher voltage than that availablethrough diode 185B, to allow the power signal to be the dominant voltageon the shared conductors.

The software flowcharts in FIGS. 1-1—1-4 and FIGS. 1A-1—1A-9 can bemodified by those skilled in the art to conform to the addition of adiode 185 in FIG. 6E (or in FIG. 6F-1). Elimination of the softwaresteps which are used to verify a removal and reinsertion of a maleconnector 132 are REM'ed out. These are steps 716-758 in FIGS. 1-1—1-4,and steps 920-938, and 991-971 in FIGS. 1A-1—1A-9. Also, as previouslynoted, accommodation is made for the depressed voltage values acquiredthrough diode 185. Since the depressed values are a constant, allvoltages (e.g., Vmin, Vmax, etc.) are uniformly depressed, resulting inwhat will appear to be battery voltage values that suggest a furtherstate of discharge than is actually present. Look-up table 799 in FIG.15, in particular, would be skewed if acquired voltage values are notreadjusted. The simplest approach is to add a voltage compensatingfactor or zero out the error created by diode 185 (FIG. 6E) at the timeeach voltage value is acquired, and prior to any voltage comparisons, orreferences to various look-up tables.

A power FET can be used in place of diode 185 in FIG. 6E, providing thatthere is an MCU (or equivalent controller) available in battery pack134. Such an MCU 102 D is indicated in FIG. 13A, residing in batterypack 508B. The power FET would be switched in and out of the circuit, ascontrolled by the MCU. Those skilled in the art will be able tointegrate a controllable FET switch into a battery circuit, using theinformation provided here regarding the placement and operation of adiode 185.

In summary, in the non-limiting examples above of the addition of adiode 185, (or equivalents such as a power FET) either in a batterycircuit (FIG. 6E), or in a connector 132A (FIGS. 6F, and 6F-1), such achange in the circuitry eliminates activities associated with an enduser reconfiguring the position of a male connector. As such, it is thepreferred method of the connector hardware of the invention. Software101 (FIGS. 1-1—1-4) and software 800 (FIGS. 1A-1—1A-9) employ stepswhich assume that a two-position male connector 132 (FIGS. 6, 6A, 6B and6C) is being used. This assumed connector modality better illustratesthe flexibility and hardware identification capabilities in bothsoftware flowcharts. Both software processes are easily modified bythose skilled in the art to accommodate a single-insertion maleconnector.

For further information on the use of diodes, see the section “DiodeDepression.”

Smart Battery Circuits

Smart battery packs are addressed in FIGS. 9A-D. Four possible wiringdiagrams show power conductors configured analogous to FIG. 6-6C. Twomajor variants are shown as FIG. 9A and FIG. 9C. These differ in whereone of the power conductors ((+) or (−)) is rerouted . . . either aheador behind smart circuit 366. If the smart circuit design requires one ofthe output powerlines 368 or 376 to be electrically attached to smartcircuit 366, then the wiring configurations in FIGS. 9A or B isappropriate. In these two models, which only differ from each other intheir polarity, disrupted powerline 388 is upstream of smart circuit366. Essentially, external power supply 398 replaces battery cells 384.The downstream smart circuit 366 does not know that power is not comingfrom cells 384, so the entire system, including the corresponding“smart” circuitry in the associated powered device, operates normally.

Critical data values from smart circuit 366 in FIGS. 9A and 9B are notdisabled. The battery cells 384, now replaced in the power circuit bypower supply 398, deliver adequate voltage in excess of the hostsystem's Vmin requirement. Software 101 and 800 in FIGS. 1-1—1-4 andFIGS. 1A-1—1A-9, respectively, always round to the next highest voltageafter performing its various calculations, so that a generous inputvoltage is detected on line 388 in FIGS. 9A and B. Voltage drop towardVmin is usually a prime indicator for a charge. In smart batteryimplementations, the battery is the system master, and initiates thecharging process.

FIGS. 9C and D represent alternative modalities to the wiring schema inFIGS. 9A and 9B. Powerline 376 is disrupted downstream of smart circuit366. This takes smart circuit 366 out of the host system's data loop. Incertain implementations, this is desirable, especially for those smartcircuits which rely on cell capacity (instead of voltage) to determinewhen charging is necessary. In most battery packs, the choice of whichof the four modalities indicated that works best is somewhatinconsequential, as it relates to battery charging. There is no externalAC/DC power at a host device's primary power port. Since the walladapter is not connected, there is no power available to the batterycharging circuit in the host device! Therefore, the choice of wiringschema is only predicated on the host system's need to acknowledge datafrom the modified battery system. Because there are so many variants of“smart” battery implementations, the correct choice can only be arrivedat by empirical testing. The relationship of cell voltages to Vmin andcharge requests in smart battery systems can be better understood byreviewing Sunny Wan's study “The Chemistry of Rechargeable Batteries.”Cadex Electronics, Inc. 7400 MacPherson Avenue,

Burnaby, BC, Canada V5J 5B6. That company's “Batteries in a PortableWorld” is also a good basic primer.

Alternative Interfaces

Male connector 132 in FIGS. 6-6D, and 8 is not the only method ofisolating a battery (s) 182 from a powered device 136. As non-limitingexamples, FIGS. 10, 11 (and 13 schematically) show externally attachedinterfaces that provide a suitable way to power a host device through abattery compartment, while maintaining analog (power) and digital (datawhere applicable) connectivity to a battery pack (see PCT PatentApplication No. PCT/US98/12807, and U.S. patent application Ser. No.10/105,489).

Approaches similar to the non-conductive insert discussed previouslyinclude eliminating the cells from a battery pack, and only using theempty plastic housing (with wires running through it) to deliver powerto a host device. While this may seem logical, the risk of misuse ofsuch an empty battery enclosure can include using the pack housing as aterrorist device. Filling the blank battery enclosure with explosivesmakes a lethal weapon of the battery pack. The application of externalpower would serve as the igniter of such an explosive package.

On a more pragmatic level, if the battery pack is a “smart” design, itwill likely be necessary to include the smart circuitry in such an emptyplastic housing, so that the powered device can communicate with itsbattery. The cost of this “empty” battery enclosure and its expensivesmart battery circuitry make it a poor substitute for a fullyoperational battery pack. The addition of battery cells to such aconstruct would not add significantly to the already high price of sucha semi-empty enclosure. Furthermore, such modified battery enclosureshave no practicality in environments where battery charging isdesirable. Transporting such empty battery packs is also aninconvenience, since even empty battery housings can be quite bulky. Forexample, a Digital HiNote Ultra 2000 laptop's battery pack measures¾×2¼×11.″

Since a powered device's battery serves a vital UPS function, shouldexternal power be unexpectedly disrupted, an empty plastic housingremoves a key safety feature. Without a battery back-up, valuable datacan be lost in a power-loss-precipitated system crash.

Conductors and Insulators

Male connector 132 in FIG. 6A is expressed as a flat-bladed assembly132, comprised of two insulator layers 204 and 208, and two conductivelayers 202 and 206. These layers are interleaved so that the outer layeron one side of the “blade” is an insulator 208, while the outer layer onthe opposite face is a conductor 202. As configured in FIGS. 6-6D,conductor 202 always is negative (−), while conductor 206 is alwayspositive (+).

The polarity of conductors 202 and 206 is not limited to a negative (−)line being broken by the insertion of a blade assembly 132 into a matingfemale assembly in battery pack 134 in FIGS. 6-6C. A positive (+)conductor can be interrupted instead, to ensure that the cells within abattery pack are removed from an active circuit, as illustrated in FIG.9D. So too, in some implementations, it could be necessary to disruptonly one data line (should there be data and power lines available), toachieve the effect of disabling the battery pack. As previously notedunder “Safely Disabling the Battery,” certain powered devices mayrequire a data link between a battery pack and the host system to bepreserved in order for the device to operate. In such implementations,disrupting the positive (+) power conductor can still provide datacommunications, if the negative (−) power line is used in conjunctionwith one or more of the data lines. Still other non-limiting examples ofpreserving a powered device's functionality include disrupting only adata line (for example, the “C” (Clock) line), so that the datacommunications can still occur, but without sufficient capabilities tolet the battery pack charge or perform other undesirable functions.

Software 101 and 800 can be used without the full A/D functions definedin FIGS. 1-1—1-4 and FIGS. 1A-1—1A-9, respectively. As non-limitingexamples, battery pack “design” voltage, and actual voltage, are readilyavailable from a “smart” battery's internal data registers. Instead ofacquiring analog data on voltage and current, as software 101 and 800prescribe, an alternative modality is to acquire digital data. The A/Dfunctions would still be necessary, in such examples, for sensing otherpower functions, such as the output voltage of a power supply 122 inFIG. 2. The hardware required to acquire digital data can include adifferent “key” connector interface 132 between a battery pack 134 and amodule 100. FIG. 8 illustrates a multi contact male connector that iscapable of being both power and data enabled.

When male connector 132 in FIG. 6B is inserted into mating connectorassembly in battery pack 134—to create construct 212—conductor 202 ofmale connector 132 is electrically connected to battery cell(s) 182 atspring contact 176, via power conductor 184. Conductor 206 in maleconnector 132 is electrically connected to the positive side of batterycell(s) 182 by spring contact 180 and power lead 188A and 188. In thisconfiguration, the voltage of battery cell(s) 182 can be read by anexternal power source. A non-limiting example of that external powersource is represented as hardware assembly 100 in FIG. 2, specificallyMCU 102's A/D ports in FIG. 2A. A/D I/O port 110 reads no-load voltage,while A/D port 106 and 112 read voltage across loads 108 and 108Arespectively.

Thus, battery cell(s) 182 in FIG. 6B deliver a positive (+) power signalalong power lead 188 to T-intersection 190, than along lead 188A tospring contact 180. There, the positive (+) power signal is transferredto male connector 132's conductor 206 (see FIG. 6A), then out to a powerlead 114 or 116 in cable 115 (FIGS. 2 and 2A).

Battery cell(s) 182 in FIG. 6B deliver a negative (−) power signal alongpower lead 184 to spring contact 176. There, the negative (−) powersignal is transferred to male connector 132's conductor 202 (see FIG.6A), then out to powerline 114 or 116 (FIG. 2 and 2A).

The operation of assembly 212A (FIG. 6B) and 212B (FIG. 6C) assumes areasonably quick removal of male connector 132 from battery pack 134.There is a transient moment when spring contacts 176 and 178 arereclosing to each other. Laptops typically have capacitor circuits whichprovide a few milliseconds of hold-up time. This is usually toaccommodate minor irregularities in the electrical interface between thebattery housing 134's contacts 174 and 175 and the mating contacts 190and 200 in the powered device 136. Spring clips are often used ascontacts 198 and 200, so minor intermittent electrical contact isexpected, as the battery pack can shift as a laptop is being carried, ormoved around on a desk, while operational.

Referencing male connector 132 in FIG. 6D, the end of the “blade” istapered to a thin edge. Being conductive, the shape of this tip allows avirtually continuous power flow at spring clips 176 and 178 in FIG. 6 asthe connector blade tip 548 in FIG. 6D is being inserted or withdrawn.

Should there be a need to keep power flowing more reliably betweenspring contacts 176 and 178 in FIG. 6, blade tip 548 in FIG. 6D (and anyequivalents) can be gold plated, as well as contacts 176 and 178.Furthermore, the geometry of the curved portion of the “throat” betweenspring clips 176 and 178 can be contoured to allow the mating surfacesof clips 176 and 178 to make reliable contact with each other before theelectro-mechanical contact with a blade tip 548 in FIG. 6D isdisconnected. This may be nit-picking, especially since it is notanticipated that there will be situations in which powered device 136 inFIG. 6 is still turned on when “key” connector 132 is voluntarilywithdrawn. In unanticipated events like a user tripping on a cord anddisconnecting it, the contacts 176 and 178 are electrically closed in amatter of a few microseconds, typically.

Multi-Contact Connectors

FIG. 8 illustrates a multi-contact male connector 290 that is capable ofconducting both digital and analog data (see U.S. Pat. Application Ser.No. 09/37/781, and International Patent Application No. PCT/US99/19181).

FIG. 8 represents a different modality of a male connector 132 in FIGS.6-6D. The eight conductive contacts 306, 308, 310, 312, 320, 324, 326and 328 can be assigned analog and/or digital lines. For example,contact 320 is an analog (−) power contact, while contact 324 isassigned to the (“T”) Temperature digital data line. Contact 326 is(“D”) data, and 328 is (“C”) clock as representing the traditionalfive-conductor wiring schema of a smart battery (reference FIG. 9A-C andelsewhere). As shown here, male connector 290's point 316 can berendered conductive, to accommodate a fifth (+) line to yield full smartdata and power connectivity between an external power source, a batteryand a powered device. If the goal is to disable battery charging,typically only one conductor of the five need be disrupted (thatparticular power or data line can vary from battery to battery, based ona manufacturer's implementation of smart battery communication).

In FIG. 8, contacts 306, 308, 310 and 312 are non-functional. They neednot be present at all in most configurations. They are shown herebecause some battery or host system implementations can require them tobe jumpered, have a resistive load or, in instances where a device inthe system needs an identifier to operate, provide access to a readablechip (not shown).

For example, Castleman's U.S. Pat. No. 5,570,002 requires a DallasSemiconductor chip to be read. This chip identifies the output voltageof an external power source. However, since Castleman restricted hispatent to the primary power port of a host system, and did not addressavailable data at a battery port, he overlooked the readily availablesmart chip in a smart battery. This smart chip has some 32 dataregisters, one of which is the battery manufacturer's design voltage.

By using a “dumb” connector 290 in FIG. 8, contacts 320 (−) and 326 (D)will deliver the battery's design voltage from the battery pack's smartcircuit, without the need for Castleman's proprietary and dedicated chipembedded in a cord or connector. It should also be noted that, whileCastleman suggests that power-related information can be elsewhere inthe host system (such as in ROM and RAM), the SMBus Smart Batteryspecifications specifically preclude access to smart battery data at thesoftware level, as well as to any existing analog or digital ports on ahost device. Castleman allows only for data access at a host device'spower or data ports, so any specific power data from a smart battery isnot available to Castleman's invention, because the SMBus is a closedsystem, not accessible from data or power ports known to Castleman.Therefore, the only practical method of accessing voltage data from anembedded chip is to access the smart battery chip via a newly-createdpower and data port, as defined in this invention.

Because there are so many possible variants of smart (and dumb) batterycircuits, it is impractical to document every modality here. However,the basic male connector 132 in FIGS. 6A-D accommodates the vastmajority of battery packs. Male connector 290 in FIG. 8 is useful insituations where the acquisition of digital data is required, althoughit can be used in non-data implementations for power only.

Male connector 290 in FIG. 8 is designed to rotate like a key inside amating female connector (not shown), instead of being removed, rotatedand reinserted, as does removable connector 540 in FIG. 6D. The eightcontacts 306, 308, 310, 312, 320, 324, 326, and 328 are offset andstaggered along the length of insulated shaft 322. By off-setting thecontacts, there can be as many as 16 mating contacts in a battery pack,so that a plurality of data paths can be created as male connector 290is rotated between two positions.

The 16 contacts would result from a two-position rotation, whereby all 8contacts are active in each of those two positions.

Sets of mating female contacts align with connector 290 (FIG. 8) at180-degree opposing locations, so that there are at least twoclosed-circuit positions as connector 290 is rotated. Shaft 322 is widerthan its height dimension to create pressure against mating contacts asthe male “key” is a rotated. Spade-shaped tip 316 keeps longitudinalalignment of connector contacts to mating contacts, and also serves tostop over-rotation as the flanges 318 block against stops in a femalereceptacle (further details of the female receptacle are defined in U.S.patent application Ser. No. 09/378,781, and International PatentApplication No. PCT/US99/19181).

FIG. 8 shows five wires 292, 294, 296, 298, and 299 attached toconnector 290. As configured here, only powerlines 292 (attached tocontact pad 320) and 299 (attached to conductive tip 316) are minimallyrequired for system operation. Connector tip 316 is utilized in thisnon-limiting example as making electrically conductive to the (+)contact in the battery pack. If there is a shared ground, only onecontact (here 316) need be electrically active. In the example of wiringin FIG. 8, wires 294, 296, and 298 are data lines, and are typically notessential to the operation of software 101 and 800 in FIGS. 1-1—1-4 andFIGS. 1A-1—1A-9 respectively. To reduce wire diameter and yet preservethe opportunity to access any of the three data contacts “T,” “D,” or“C,” a mux or n-signal switch (not shown) can be incorporated in shift322 or connector handle assembly 300/302 of connector 290. Such a switchallows a less-cumbersome 3-wire cord that has all of the data functionsof a five-conductor cord when using a Dallas 1-Wire approach.

Two-Line Bi-directional Data

Certain “smart” data communications systems can be made to operate withtwo-conductor cords, by implementing a buffer or memory on a chip totemporarily hold data(see element 551 in FIG. 2), prior to muxing thelines. Thus, a chip like the Dallas Semiconductor (Dallas, Tex.) DS2437“Smart Battery Monitor” can be embedded in a male connector 290 (FIG.8), 540 in FIG. 6D, or equivalent. Three of the eight contacts shown inFIG. 8 are then active between connector 290 and a battery pack having amating connector. This Dallas chip reads real-time data as A/Dinformation, unlike Castleman's schema which has all functional datapre-programmed in a digitally-readable chip at the time of manufacture.Thus, the implementation described here of acquiring a power device'spower values at the time of use, is not used by Castleman. Nor is thestoring of values from a battery, either pre-stored, or created whilethe system is in use, then stored for later access, addressed byCastleman. Castleman deals with the voltages that power a host device atits primary power port, and not with the different voltage values usedto power that same host device through its battery port.

Data is stored on the Dallas DS2437 (or equivalent) chip in its 40 bytesof EEPROM memory. This memory, 551 in FIG. 2, as designed by DallasSemiconductor, can survive even short circuits, so its use in aline-switching circuit is beneficial.

Data now available from the Dallas DS2437 chip is available to anexternal device over a two-conductor cord, by including either a mux ormicrocontroller in a male connector 290 (or equivalent). Amicrocontroller, such as the Dallas Semiconductor DS87C530, or theMitsubishi M37515 (or equivalents) can be used to create a simplexswitch, via a multiplexer, that allows two lines to be shared forbi-directional data. There would be no frame ground present. Connect theTx-to-Rx lines on an RS 232 driver receive chip. Hook the line to theinput side of the driver and the output of the receive. The multiplexerasserts control over the lines. The two wires are thus signal andground. Such muxed lines on a serial port require software protocolcontrols for send/receive collision avoidance.

Instead of muxing the lines, another approach is to use RS485transceiver chips, to establish CMOS signals on one side (receive out,driver in) and a send/receive pin. The output is a 5-volt differentialas simplex. In operation, a “slave” processor (as circuitry in maleconnector 290) is in “listen” mode, until another processor (“master” inan external power supply) sends a command to acquire and send data.Software allows for some period of latency while the slave acquiresdata, such as actual voltage. Once the data is sent, the slave goes backto a listen mode. One line works in both directions, as a shared dataline. RS485 chips from National Semiconductor (Santa Clara, Calif.) areavailable that share common differential lines and have common CMOSlines with transmit and receive signals.

At the MCU, two general-purpose I/O port pins are used, one of which isthe Tx/Rx pin. Software writes a 0 to put the line in a transmit mode,then changes the pin back to a listen mode. The communications protocolcan be loaded to the 16 Kb of EPROM on the Dallas SemiconductorDS87C530, for example.

Power on the two-conductors is +5 VDC, which can be generated by aregulated battery voltage in the circuit. This is preferable to usingthe variable output voltage of an external power supply. Power supplyshould be shut down when the system is in a communications mode, to freethe two power conductors for data. However a power supply can deliver +5VDC to its microcontroller, but not apply such a voltage directly on thepower/data conductors directly. Those skilled in the art can executesuch two-wired communications schema as defined above.

Flex-Connector Interface

FIG. 7 shows a simplified power interface 250 with a battery bay 280. Athin flexible insulator 262 uses conductive traces 264, 266, 268, and272 to interact with a rechargeable-battery-powered device 284. Twoconductors 264 and 266, are separated by insulator layer 262. Conductivetraces 272 and 268 are similarly insulated by non-conductive layer 262.Contact areas of traces 264 and 272 connect to battery 288 at cellcontacts 274 and 276. Opposing contact areas of traces 266 and 268interface with powered device 284's electrical contacts 278 and 276A.

When inserted between contacts 274 and 276 of battery cells 288 in FIG.7, and electrical contacts 276A and 278 in battery cavity 280, flexassembly 250 creates two discrete circuits. One circuit is to thebatteries comprised of traces 264 and 272, while the opposing contacts266 and 268 electrically create a circuit to host device 284, so thattraces 266 and 268 create a circuit that effectively bypasses cells 288.This allows external power sources, such as a power supply and/orbattery charger, to operate either simultaneously or independently, topower a powered device 284, and to charge a battery, both functionsbeing performed on the discrete electrical paths created by aflex-connector 250.

Like FIG. 8's multi-conductor connector, a flex-connector 250 in FIG. 7has four discrete wires 252, 254, 256, 258. Unlike connector 290 in FIG.8, where low-power data lines can be switched in and out of a cable by amux or n-signal switch, the flex-connector assembly in FIG. 7 has onlypower conductors.

Switching power conductors in order to minimize cable size could requirea substantial circuit of power FETS. However, because assembly 250 isdesigned to be compatible with software 101 and 800 in FIGS. 1-1—1-4 andFIGS. 1A-1—1A-9, continuous power along any conductor pair is notrequired so the use of switching FETS is acceptable. With afour-conductor cable as shown in FIG. 7, battery 288 can be hardwiredfor continuous monitoring. Software 101 and 800 FIGS. 1-1—1-4 and FIGS.1A-1—1A-9, respectively) can be modified to allow for four-conductoruse, and references to insertion/retraction (or, in the alternative,rotation) of a male connector in the software Specification would not berequired. Either the use of power switches, or simply relying on thecontinuous monitoring available from a four-conductor system, will workwith the flowchart of software 101 and 800.

If a four-line cable is acceptable, the low power requirements of thetwo-cell (1.5-3 volts depending on cell chemistry) circuit allows forsmall wire gauges on lines 252 and 258. Conductors 254 and 256 can bemore substantial, since the current load of device 284 is unknown.

Assembly 250 in FIG. 7 has the advantage of being left permanently, orsemi-permanently in place. A simple 4-pin connector can be fitted to theflex assembly 250 where wires 252, 254, 256 and 258 interface. Thisconnector is designed to accommodate the previously-mentioned switchingcircuit. At such low power as indicated here, an attenuator n-signalswitch, such as those available from Maxim Integrated Products(Sunnyvale, Calif.) can be used. It can be wired so that voltages fromeither cells 288 or from a power supply (not shown, but referenced as anembedded power supply 122 in FIGS. 1-1—1-4, or an external powerconverter 122A in FIG. 13A) activate the switch positions.

Data Acquisition

An external power source (such as hardware assembly 100 in FIG. 2, orpower box 400 in FIG. 13A) can read the actual voltage (both load andno-load) of battery cell(s) 182 (as in FIG. 6 andidentified as batterypack 134 in FIG. 2). This information is acquired through the variousI/O pins of an A/D converter 104A (see FIGS. 2 and 2A), and eitherstored in memory 104B, or immediately used to compute a valid voltagevalue to which a configurable power supply 122's output can be set.

Once the correct voltage value of battery cell(s) in pack 134 in FIG. 2has been determined—which is one of the processes software 101 and 800in FIGS. 1-1—1-4 and FIGS. 1A-1—1A-9 performs—that voltage value is usedto modify the Vout of a power supply 122. How that Vout value is arrivedat is discussed in the “Software Operation” section.

Power Delivery

Connector 132 in FIGS. 6-6C is first addressed in software 101 and 800(FIGS. 1-1—1-4 and FIGS. 1A-1—1A-9) as being disconnected. Software 101knows each position of connector 132 as it is repositioned through thevarious machine states in the software flowchart. The most importantconnector state is when a male connector is disconnected from itsassociated battery pack 134. The disconnected state indicates tosoftware 101 (and 800) that a process is expected to start, or has justbeen completed. The state of male connector 132 provides a confirmationthat the software logic-flow and state changes have been observed by theuser.

A male connector 540 and its associated power cord, as an assembly, hasa known resistive value. That value is fixed at the time of manufacture;pre-calibrated to be all of the same matched impedance. A connectorcover 530 in FIG. 6D, or equivalent, can be employed. Cover 530 hasembedded resistor 534 (or some other resistively-stable component) thatexpresses a repeated and readily-identified Ohm value. When cover 530 isin place, software 101 (FIGS. 1-1—1-4) acknowledges the identificationof resistive element 534 as a “pre-operational” state, i.e., a user ispresent and has attached connector 540 to its power cord.

This state when the resistive element in connector cover 530 (FIG. 6D)is detected is important, because software 101 (and 800) shut down powersupply 122 (FIG. 2). There is no power output—except for a nominalvoltage in order to monitor changes in line resistance. This is a safetyfeature. One of the intended uses of the system shown in FIG. 2 is on anairplane. The original specification for power systems at a passengerseat (ARINC Specification 628, Part 2) provided for an intentional shortin the Remote Power Outlet (RPO) to indicate that a power cable has beenattached by a passenger. Should the invention here use such a shortedconnector, software 101 and 800 can identify a pre-operational statewhen a passenger attaches a power cord to the RPO. Information on ARINCspecifications is available from Aeronautical Radio, Inc., (Annapolis,Md.). Note that ARINC Specification 628, Part 2, was not approved as ofthe time of this writing.

The hardware device states can apply to the operation of a power cord onan embedded retractor reel 550 in FIG. 2B. In that mode, either themotion of the cable extension incorporates a sensor that “awakens” powermodule 100 (FIG. 2), or MCU 102 (FIG. 2A) samples powerline impedance asan indicator of impending passenger activity.

Power supply 122 in FIG. 2 turns on periodically at a low outputvoltage, e.g., 3 VDC or less, to perform line load impedance readings.If the load value at A/D I/O port 110 (FIG. 2A) is the same as a storedvalue that equates (in look-up table 990 in FIG. 20) to a blank cable(no removable connector such as 540 in FIG. 6D present), then powersupply 122 shuts down until the next polling test. If connector 540 isremovable, instead of permanently affixed to the end of a power cable,as shown in FIG. 6D, then sensing the presence of removable connector540 is an important indicator of a state change that will result infurther software and hardware activity.

Once connector 540 in FIG. 6D is sensed by an MCU 102 (FIG. 2), eitherwith or without its connector cover 530, hardware assembly 100 in FIG. 2goes to a full ON state. Software 101 or 800 puts. MCU 102 into anaccelerated powerline sampling process. That process is to detect theremoval of cover 530, in anticipation of the insertion of connector 540into a battery pack (see FIGS. 6-6C). If connector 540, or anequivalent, is manufactured without a cover 530, then a resistiveelement 534 (or equivalent) is embedded in the connector's shell 544.That resistive element 534 is strapped across electrically conductiveconnector elements 546 and 548 but is located within connector shell544. Note that resistive element 534 in cover 530 has conductive pads532 and 536. When cover 530 is in place, pads 532 and 536 makeelectrical contact with conductive surfaces 548 and 546 respectively onconnector 540.

Thus, cover 530 in FIG. 6D (with an internal resistive element 534, oran equivalent) is a beneficial aid to the operation of power system 100in FIG. 2. However, it is not indispensable, since other indicators ofthe state of a connector 540 in FIG. 6D can be reliably determined byother means, such as the extension of a cable on a retractor reel, as inelement 550 in FIG. 2B.

Resistive Identifiers in Cords

Nesco Battery Company (Van Nuys, Calf.) manufactures a “Smart Cord”which uses a variety of resistors in its powerline connector to identifyor distinguish the output voltage of a “Smart Adapter.” Unlike the useof a resistive element 534 in a removable connector cover 530 (FIG. 6D),the Nesco patent uses the resistive load to decrease a power supply'soutput voltage. The resistor element is used as a resistor, and not asan identifier. There is no feedback to an A/D converter or processor, sothe resistor element used by Nesco is a passive electrical element, forpurposes of its load changing (voltage reduction) ability. Also, theNesco patent does not allow for removal of the resistive element, whileconnector cover 530 is removable, thus taking the resistive element outof the active circuit.

Although the description above contains many specifications, theseshould not be construed as limiting the scope of the invention, but asmerely providing illustrations of some of the presently-preferredembodiments of this invention.

Software to Configure Battery and Power Delivery Hardware

Note: Matter presented in this section is often also discussed in othersoftware sections, as well as throughout the preceding hardwaresections. Any relevant matter is assumed to be included here byreference, as if it were presented here in full.

The software herein interacts with a multiplicity of hardware devices,defined above as “Hardware to Configure Battery and Power DeliverySoftware,” to configure a power supply output, and/or, in certainmodalities, to detect and respond to battery-related activities, such asbattery charging.

Software 101 (FIGS. 1-1—1-4) and software 800 (FIGS. 1A-1—1A-9) havesignificant commonalities. Voltage and current sensing processes arecommon to both, as well as power supply output-voltage determination.While not limiting, software 101 is usually specific to an embeddedhardware platform, while software 800 usually runs on an in-line, cordedpower conversion adapter. One non-limiting assumed modality is that anin-line, corded adapter (running software 800) is attached to anupstream embedded power supply assembly (running software 101). Software101 is also an abbreviated version of software 800 in certain areas,primarily in not showing every one of a number of nearly-identicalpowerline-load monitoring sequences.

Software Principals Of Operation

Software flowchart 101 in FIGS. 1-1—1-4 operates with a plurality ofhardware devices, non-limiting examples of which are described in the“Hardware” section. The general software principles of operation areshown diagrammatically in FIG. 12. Three overall types of softwareoperations are performed: data acquisition 330, processing 332, andcommand/control 334.

Data acquisition 330 operations include identifying the position of aconnector such as 132 in FIGS. 6-6C. There are three possible connectorpositions 340, as identified in chart 1001 (FIG. 17). FIG. 6 showsconnector 132 removed (not connected). FIG. 6B depicts connector 132inserted to create an electrical path that includes only battery 182(i.e., Position #1 in FIG. 17). FIG. 6C shows connector 132 inserted tocreate an electrical path bypassing battery 182, and only includingpower lines to system 136 (Position #2 in FIG. 17). Later discussiondeals with software 101's ability to correctly identify each of thesethree connector positions.

Data acquisition operation 330 in FIG. 12 includes the acquisition ofelectrical (power, or data) values 342. Only two modes exist. Theacquisition of battery voltage 354, or the verification of power supplyVout 356. These are detailed later.

Processing operation 332 in FIG. 12 includes, but is not limited to,performing various calculations 338, and/or storing various acquiredvalues 328.

Command and control operations 334 (FIG. 12) of software 101 in FIGS.1-1—-14 require only one command operation—to configure the appropriateVout 344 of a power supply. The screen display 346 capability ofsoftware 101 is optional, but should be considered in implementationbecause it assists a user in properly using connector 132 in FIGS. 6-6C.

The overall functions and operations of software 101 are comprised ofbut not limited to:

1). Acquire one or more parameters of a power signal, then by processingone or more of the power signal parameters, to achieve a useable poweroutput from a power source or supply device that delivers power to apowered device.

2). Calculate at least one parameter of an acquired power signal inorder to identify a source of power within a powered device, such as abattery, so that at least one parameter of that source of power matchesa known set of power values. For example, software 101 can oftenidentify—from a multiplicity of battery packs having different voltageratings—a reasonably accurate estimate of the manufactured voltage ofeach battery pack.

3). Monitor the operation and sequence of user activities in ameaningful way, which allows the user to have confirmation or feedbackabout the sequence of user actions required. The confirmation is alsoknown to either (or both) a power source and/or a powered device. Forexample, software 101 has knowledge of a user's actions in configuring aconnector, and the software prompts the user to proceed to a next step,or issue error warnings should user's actions not be as required.

4). Confirm a power output signal from a power source. As a non-limitingexample, software 101 can compare a manufacturers' output voltage of abattery to the output voltage of a controllable/configurable powersupply, to verify that both are either matched, or within pre-definednominal parameters.

5). Acquire power-related data by a plurality of means and store suchdata in memory so that the stored data, over time, is used as areference source for future power activities. As a non-limiting example,look-up tables are created from a database of prior operations thatbecome part of a decision-making process in software 101. The look-uptables, once created from an experiential database, contributing furtherlevels of power output signal verification.

6). Monitor operational parameters of power sources to determine if thepower sources are operating within manufacturers' definedspecifications. If a power source's performance drops below definedminimal values, software 101 alerts a user (by a number of indicators)that the power source is deficient. As a non-limiting example, software101 tracks usage as a function of possible. MTBF maturation, so that auser can replace an aged power source with a new one.

7). Control hardware, including but not limited to sequencing switches,controlling I/O ports, data lines, power-signal lines, and configuring apower supply's output.

Functions of software 101 in FIG. 1 are not limited to those describedabove, but the above non-limiting examples illustrate software processeswhich add operational value to a plurality of hardware devices.

User Operations

The user operation of various power-related hardware, as it relates tosoftware 101 in, FIGS. 1-1—1-4, is expected to be sequential. Thesequence of inserting, removing, rotating, and then reinserting aconnector 132 in FIGS. 6-6C is controlled by a user. FIG. 14 is anexample of an instruction sheet or label that prompts a user to movesequentially through the required steps with connector 132 in FIGS. 6,6B and 6C. An optional step is shown in the first instruction in FIG.14: “Close cap on ‘key’ connector.” Cap 530 is shown in FIG. 6D, and itneed not be used to achieve the functionality of software 101. Anexplanation of the use of optional cap 534 is discussed in the hardwaresection. Connector 132 can also be detachable from its power cord, sopart of the first instruction in FIG. 14 would prompt a user to attachconnector 132 to its cord. User instructions are only suggested here,and there are a number of ways such instructions—if necessary at all—canbe conveyed to a user.

Modular Software

Software 101 in FIGS. 1-1—1-4 defines a process achieved by a sequenceof steps or machine states, each of which, in and of itself, or in amultiplicity of non-limiting combinations with other discrete steps,adequately perform a desired function. Particular steps required areprimarily determined by the function to be performed, as well asavailable hardware and the hardware assembly's capabilities andconfiguration. To perform a function, software 101 must execute at leastone step defined in flowchart 101 in FIGS. 1-1—1-4.

To achieve a desired function, the sequence of steps is not limited tothat shown in FIGS. 1-1—1-4. Machine states or steps are structured tooperate in different sequences. Also, not all of the steps or machinestates need be operational for a specific hardware device or assembly ofdevices. Code for software and sequence(s) can reside on storage mediain a powered device, while other core elements can reside on a chip inan external power supply (or even its associated battery), asnon-limiting examples. Such division or duplication of software codecan, for example, be required because one device of at least the tworequired to achieve software functionality, can act as a master, whileanother device in the assembly can require equivalent software tofunction properly as a slave. It is not essential that there be morethan one hardware device in which software code is resident.

Hardware Considerations

Software 101 in FIGS. 1-1—1-4 is not limited to configuring the powerrequirements for hardware devices that have pre-stored information, oreven by a device's ability to store information. Nor is software 101limited in any way to delivering power to hardware devices which arecomprised of memory, computer chips or DSPs, pre-determined resistorvalues, cords with pre-configured components (resistive or otherwise),or data storage. In actuality, software 101 is capable of powerconfiguration and delivery functions with such diverse battery-powereddevices as an ordinary flashlight, or a laptop computer.

As a non-limiting example, software 101 can reside in a configurablepower supply embedded behind the dashboard of an automobile, with anavailable electrical outlet comprised of at least two power contacts(e.g., a cigarette lighter outlet). A controllable power supply can beconfigured, by the use of software 101, to automatically power a 24-voltlantern, then a 9-volt portable radio, as well as a 5.5-volt cellularphone. Each of these devices can be connected to this “universal” powerport without any intermediate power-conversion adapters. Thus, forexample, software 101 provides functionality to an automotive distresssituation, where a plurality of diverse input-voltage devices arerequired to operate properly without intermediate power conversionadapters.

Minimal Software States

Software 101 in FIGS. 1-1—1-4 need only perform minimal processes toachieve the automotive functions as exemplified above. The hardwareconfiguration in FIG. 7 represents a non-limiting example of a simplebattery-powered device 284, like a flashlight, TV remote control, orportable radio. Software 101, to deliver a compatible power signal froman embedded power supply behind a car's dashboard, need only readbattery 288's voltage, and configure an external power supply (notshown, but the equivalent of a power box 400 in FIG. 13A) to match thatvoltage. Thus, if the two cells which comprise battery 288 in FIG. 7 areNi-Cads, the battery's voltage would be 2.50 VDC. Software 101configures the voltage output of a controllable power supply to 2.60VDC.

Software 101, if necessary, confirms and continuously monitors anexternal power supply's output voltage, but such confirmation is notessential to the proper functioning of device 284.

Software 101 in FIGS. 1-1—1-4 acquires a battery's voltage in severalmodes. “Vmax” 658 is the no-load voltage of a battery, while “Vmin” 680is the under-load voltage of a battery. Software 101 can be programmedto look at either or both Vmax or Vmin values, but it must acquire atleast one. The selection of Vmax or Vmin is typically not essential. Apowered device with a battery source is designed to accept a Vmaxvoltage, since all batteries have an initial “pulse” voltage which canbe a substantially higher voltage spike than a continuous Vmax.Therefore, matching Vmax is typically acceptable, if only one voltageparameter is to be acquired.

Vmin, the under-load voltage value of a battery, is acquired in certainapplications. The significance of Vmin is that it may, under certainconditions, also be a viable voltage parameter for an external powersupply to match or to use as a basis of a calculation. The conditionswhich determine the validity of Vmin are:

1). The type of device being powered. For example, complex powereddevices such as laptop computers have a pre-determined shut-down or.“not-to-exceed” minimum battery output voltage. This shutdown voltage ispre-set by the manufacturer of the powered device to prevent totaldischarge of a battery. In such complex devices as a laptop computer,the user usually receives audible and visual prompts that the remainingcapacity of its battery source is approaching a critical state. While a“fuel gauge” which reads and monitors battery capacity can be used totrigger such alerts, a voltage parameter is often used to triggeralerts, as well as an eventual shutdown. The voltage parameter forpowered device's pre-determined shut-down is always set enough above thebattery cell's minimal safe discharge voltage so that cell reversal doesnot occur.

2). In simple powered devices, such as a flashlight, there may be nopre-determined minimum battery voltage values. A flashlight, because ofcost considerations, is typically designed so that the consumer isresponsible for keeping the battery charged. The only indicator that thebattery is at Vmin may be that the light bulb no longer glows.

3). Battery care and charge/discharge life expectancy are determinantsof a valid Vmin. Batteries self-discharge over time. If a battery hasnot been charge in 30 days, it's under-load output voltage could havegone below its powered device's minimum voltage shut-down value,especially is the battery capacity was nearly depleted when stored.Should the time between recharges become excessive, the battery may beapproaching (or have exceeded) its non-recoverable voltage value.

4). Cell chemistry determines the non-recoverable voltage of a battery.FIG. 15 is a look-up table of common cell chemistries showing recognizedmanufacturer's design cell voltage, and a not-to-exceed minimum cellvoltage. Below the minimum cell voltages indicated, damage to the cellcan occur, primarily from cell polarity reversal. Once cells arereversed in polarity, it is usually impossible to recover the battery,even with charging.

5). Memory is a charge/discharge characteristic of some cellchemistries. Primarily Ni-Cad (and some NiMH) cells can exhibit aninduced voltage threshold below which the cell will no longer discharge.Repeated operations of a powered device which don't filly dischargecells usually causes memory. The impact of memory on software 101 inFIGS. 1-1—1-4 is not significant, because a memory-induced Vmin valuewill always be above the cell-chemistry-determined manufacturers' designvoltage, as indicated in item #4 above.

6). Cell “recovery” is a characteristic of many battery chemistrieswhich causes a drained battery to have transient recovery of voltageafter a period of rest. This is often observed when a flashlight thatwould not operate is turned on hours later, and the bulb burns for abrief moment. This characteristic of battery cells is a positivecharacteristic that makes it possible to acquire a valid Vmax from abattery that is, for all intents and purposes, fully discharged. That'swhy software 101 in FIGS. 1-1—1-4 performs a Vmin under-load tests atthe early part of the software processes, thus anticipating some minimalamount of cell recovery. Further under-load tests can produce sporadicvoltage-acquisition values. If so, software 101 relies on the first Vmintest as the most valid and references that as a benchmark.

The above-defined characteristics of batteries and powered devices donot always have to be accounted for in software. Depending on intendedsoftware and hardware function(s), types of batteries expected tointerface with software 101, and voltage-design parameters of differenttypes of intended powered devices, software 101 may not need to considerany of these issues. However, an awareness of the implications of usinga Vmin approach to software should be evaluated when writing code forreal-world applications.

Real-World Battery Considerations

In the real world, powered device usage minimizes many of theabove-mentioned issues with acquiring useful Vmin voltage values from abattery. Laptop computers, for example, are treated more scrupulouslythan a rechargeable flashlight. Users tend to keep laptop batteriescharged, because these devices are usually plugged into a wall outletfor much of their useful lives. Also, today's laptop batteries use“memory-less” cell chemistries such as Li-Ion and NiMH. On the otherhand, some laptop purchasers buy a spare battery, which sometimes can gounattended in a desk drawer for many months.

While not included in hardware, a battery tester/reconditioner can beincluded in an assembly 100 in FIG. 2. This is indicated in situationswhere a large number of mixed-type powered devices are attaching to ahardware assembly 100 (FIG. 2). As a non-limiting example, on acommercial aircraft, passengers may be connecting everything fromcellular phones, laptops, rechargeable electric shavers, etc., to anembedded power assembly 100. Should battery charging be one of thefunctions prescribed for software 101 in FIGS. 1-1—1-4 and relatedhardware, a battery tester and reconditioner screens many of the issuesrelating to Vmin and Vmax.

Such testers/reconditioners as manufactured by Cadex Electronics(Burnaby, BC, Canada), enhance software 101 by evaluating battery aging,cell chemistry, and even voltage parameters. In such a modality,software 101 operates in a data acquisition mode and captures batteryvalues and functional parameters. Much of this data can be acquired aspre-processed digital or analog values, so that software 101 operates toevaluate known data values, and configures appropriate hardware. Whilenot shown, such a software program that operates with a batterytester/conditioner can be written by those skilled in the art, based oninformation herein.

Voltage and Current Define Operations

Software 101 acquires voltage and current readings and correlates themto user actions. Actions such as connecting a power cord to a maleconnector, and detecting the position of a male connector 132 in FIG.6-6C are determined by states which software 101 defines in terms ofvoltage, or line current.

Software 101 operates with only two basic acquisition modes, readingvoltage and sensing current.

In reference to FIG. 17, reading voltage is used to acquire power-signalvalues of a battery, as previously discussed. Detecting voltage is alsoused to determine states of a male connector 132 in FIGS. 6-6C. Ifvoltage flow is detected along power lines 115 in FIG. 2, the power canonly be from battery 134, or from external power supply 122. Whensoftware 101 commands the operations of power supply 122, and voltagedetected on power lines 115 when power supply 122 is shut down must comefrom battery 134. Since connector 132 in FIGS. 6-6C (and elsewhere) canonly be in the Position #1 shown in FIG. 6B, software 101 identifies theposition of connector 132 as being in the position shown in FIG. 6B bysensing battery voltage.

Connector 132's Position #2 from FIG. 17, shown in FIG. 6C, is onlysubtly different from connector 132's “Not Connected” position shown inFIG. 6. Both positions have connector 132 in a non-voltage carryingmodality, so detecting voltage with software 101 is not appropriate.Sensing current as a software acquisition value resolves the issue.Connector 132 in a “Not Connected” position shown in FIG. 6 is onlydifferent from that same connector 132 as shown inserted in FIG. 6C(Position #2).

When connector 132 is in its Position #2 from FIG. 17, as shown in FIG.6C, an electrical load is available that is not present when connector132 is in the “Not Connected” position shown in FIG. 6. This load iscreated by the internal circuitry of a powered device's 136 systemwiring. Such circuitry would include loads imposed by capacitorscommonly used to allow a small hold-up time related to contacts atsystem-to-battery connector 196. Also present can be circuits whichinclude battery selectors, various power switches, voltage regulators,an internal charger etc. Any or all of these can be present, whichprovides sufficiently identifiable resistive load to differentiate acurrent reading from one taken on a no-load powerline (See discussionand Chart of FIG. 2A's A/D ports in the “Hardware” section).

Table 1001 in FIG. 17 is a description of connector positions, withcorresponding software sensing functions. Software 101 in FIGS. 1-1=131-4 monitors load on powerlines 115 in FIG. 2. Conductors 114 and 116,along with unattached connector 132 constitute a very minimalresistance, which software 101 logs as the “Not Connected” device stateof FIG. 17. FIG. 6D illustrates a removable connector cover 530, whichhas an embedded resistive element 534. Resistive element 534 has a knownresistive value, which software 101 uses as a current-sensing loadcomparator. If that known resistive value is detected by software 101 asa match, the state of connector 132 is considered to be unattached.Furthermore, the sensing and matching of element 534's resistive valuein connector cover 530 is used to indicate that a removable maleconnector 540 has been attached to the end of a powerline 115 in FIG. 2.When cover 530 is removed, software 101 senses that activity as a changein load. Software 101 then configures MCU 102, and power supply 122(FIG. 2) to commence sensing a voltage in powerlines 115.

Connector 540 in FIG. 6D (and other connector modalities shown in FIGS.7 and 8) can also have a first (or even a second) resistive element, sothat software 101 can sense that a connector 540 (or equivalent) isattached to a power cord (assuming that connector 540 is made removable,a feature which is not necessary for the proper operation of software101).

Supplemental resistive elements can consist of part of the internalwiring of a battery housing, as shown in FIG. 6C. FIG. 6E shows a diodethat will indicate some load. This will assist software 101 insituations when there is no available resistive load from a powereddevice's internal system circuitry. It can also be practical to build aresistive element into the circuitry in a battery pack as positiveindication that connector 132 is in the position shown in FIG. 6C.Resistive element 199 in FIG. 6C is optional. If used, it has aresistive value distinctively different from resistive element 534 inFIG. 6D. This allows software 101 to identify each of connector 132'stwo positions in FIGS. 6 and 6C as uniquely different and readilydistinguishable. A resistive element 199 does cause a load to battery182, so the use of such a resistive element must be viewed in light offaster battery drain.

One of the system states identified in look-up table 990 (FIG. 20) isLL⁴, a battery pack that is removed from its associated powered device.The known value of resistive element 199 in FIG. 6C is a valid indicatorof this state.

Thus, a plurality of methods of differentiating a connector 132'spositions in FIG. 6 versus FIG. 6C are all based on sensing changes inresistive loads. Power supply 122 in FIG. 2 is turned on and configuredby software 101, to output a low voltage, e.g., 3 VDC. At this lowvoltage resistive loads can be sensed on power lines 115.

Basic Software Functions for Connector Activities

A suitable software logic to determine in which position connector 132is in (FIGS. 6, 6B or 6C) is defined in FIG. 16. Software 229 in FIG. 16is a highly-simplified flowchart that isolates onlyconnector-position-determination functions. After the power supply isshut down in step 231, step 233 is a powerline voltage check. If thereis voltage detected on the powerlines, connector 132 is in its Position#1 (FIG. 6B). Since software 229 has shut down its associated powersupply in previous step 231, the only source of power in the circuit canbe the battery pack. Therefore connector 132 is in its first position inthe battery pack where it is electrically active with battery cell(s)182. If connector 132 were in the battery pack, but in its Position #2,no battery voltage would be detected on the powerlines in software step233.

A second powerline voltage check is performed in step 237. The state ofconnector 132 is unknown, because there is no battery voltage detectedon the powerlines. Connector 132 in a removed position, or in itsPosition #2 (see FIG. 17), exhibits identical voltage-detectioncharacteristics, i.e., no powerline voltage is detected.

Having detected no powerline voltage, software 229 activates itsassociated power supply. A low voltage is put on the powerlines in step241. Step 243 confirms that the voltage detected on the powerlines isfrom the power supply.

A powerline load is detected in step 245. By consulting a look-up tablesuch as in FIG. 20, the powerline load value acquired in step 245 isdetermined to match the load expected when connector 132 is insertedinto a battery pack in its Position #2 (see Identifier states LL⁴ andLL⁵ in FIG. 20). Thus, step 247 confirms that connector 132 is in itsPosition #2. Since this is the correct position for delivering power tothe battery's associated powered device, step 249 applies the correctoutput voltage at the powerlines.

Note that all error states, indicated by what are FALSE answers to anyquery statement, loop back to a power supply shutdown in step 231.

Timing Issues

Software 101 in FIGS. 1-1—1-4 monitors user actions in operatingconnector 132 in FIGS. 6-6C. While software 101 can identify each of thethree required connector positions (“Not Connected” as FIG. 6); insertedto create a circuit with battery cells (Position #1 as FIG. 6B); andinserted to create a circuit to a powered device (Position #2 as FIG.6C), the software must wait for each of the two last actions to beperformed before continuing. This creates a timing issue. A user may,for unknown reasons, take an indeterminate amount of time to moveconnector 132 from Position #1 to its next position as Position #2.

A user's actions are detectable by software 101 when inserting andremoving connector 132, as represented by “Not Connected” in FIG. 6, andPosition #1 in FIG. 6B. Software 101 sees a voltage from battery 182upon the insertion of connector 132, as represented as Position #1 inFIG. 6B. Software 101 can also, by applying a low voltage to powerlines115 (FIG. 2), monitor current load to verify that connector 132 isremoved as “Not Connected” in FIG. 6. However, a user could, whileconnector 132 is delivering the low voltage required to sample current,reinsert connector 132 in the same configuration as shown in FIG. 6Binstead of going to Position #2 in FIG. 6C. Thus reconnected as in FIG.6B a second time, battery voltage would flow along the powerlines, andinto a power supply that is outputting a low voltage. Damage to a powersupply can occur. A diode in the positive (+) output line of a powersupply (such as the representational schematic in FIGS. 4-1 and 4-2)will eliminate this. The voltage sense line at header J1, pin 20 inFIGS. 4-1 and 4-2 should be tied to the positive power output line so asnot to be impacted by the diode. Those skilled in the art willunderstand how to properly implement such a protective diode.

The addition of a diode that will protect power supply 122 in FIGS. 4-1and 4-2 also allows software 101 to turn on power supply 122 to a lowvoltage (e.g., 1.5-3.0 VDC), in anticipation of the insertion ofconnector 132 in its correct Position #2 configuration, as shown in FIG.6C. While waiting for connector 132 to be reinserted software 101continuously switches from voltage sampling to current sampling. Thisswitching assumes three dedicated A/D circuits, with a circuit 110 inFIG. 2A which samples powerline voltage, while two dedicatedcurrent-sensing circuits 106 and 112 monitor current by means of aresistive element 108 and 108A. Each resistive element has a differentresistive value, with one being approximately 50% of the anticipatedmaximum load of a powered device. FIG. 5A shows a circuit for applying aload at an A/D port, which is compatible with the circuit of a typicalMCU in FIG. 5.

Note that, as long as power supply 122's Vout is less than the battery'sVmin, there will be no contention, since the dominant higher voltagewill always control the power lines. No power will flow into a batteryat such extremely low voltages.

Should connector 132 be reinserted incorrectly, so that it is in thePosition #1 configuration shown in FIG. 6B, instead of in theanticipated Position #2 in FIG. 6C, software 101 will detect battery182's voltage values on the powerlines. An error state then occurs.Software 101 responds by shutting down power supply 122, and issues aprompt to the user (non-limiting examples of user prompts are a screendisplay (see “Power Monitor” in FIG. 18), a blinking LED, or a labelwith LED prompts in FIG. 14).

If connector 132 is correctly inserted, as illustrated in FIG. 6C,software 101 senses the load of a powered device 136 using thecurrent-sensing circuit 106 (in FIG. 2A). Vout at power supply 122 inFIGS. 4-1 and 4-2 is then changed from the low-voltage (1.5-3.0 VDC), tothe calculated voltage value from step 714 in flowchart 101 in FIGS.1-1—1-4.

Point-Count vs. Actual-Value Software Schemas

Software 101 in FIGS. 1-1—1-4 can be configured to operate in a numberof data acquisition modes. Of these, the most popular is probably a“point count” based schema, instead of an actual-acquired value model.The use of point-counts and Boolean variables is well understood bythose skilled in the art, so specifics of such software processes is notdetailed here.

Point-count based software algorithms and logic statements are preferredin the implementation of software 101. Acquisition of voltage andcurrent should be addressed as relative values, not absolutes. Batterydischarge states are relative, so that Vmax and Vmin can differ for thesame battery when sampled at different times. Ranges of battery voltagevalues are more important than absolute values. Software 101 relies onthe spread between a Vmax and Vmin to achieve a proper output voltagefrom a power supply. In one modality of software 101, acquired batteryvoltage values are arranged, from lowest to highest (see steps 913-915in FIGS. 1-1—1-4), to determine whether the original Vmax and Vmin arepotential errors.

Actual values become more accurate than a point-count software schemawhen dealing with batteries that are in a state of deep discharge. Vmaxvoltages drop off precipitously as a battery approaches completedischarge. Point counts can sometimes not be granular enough todifferentiate the two values. Software 101 in FIGS. 1-1—1-4 is notrestricted in any way to the use of only one software schema. Hybridmodalities, that use both a point count and real-values are practical,and serve well in environments where a multiplicity of battery chargestates are expected to be encountered.

Granularity of the A/D

Point-count software schemas are dependent on the bits available from anA/D converter: An 8-bit converter will offer only a 190-250 maximumpoint count across the range of values being acquired and compared. A10-bit or 12-bit A/D converter will allow significantly enhancedpoint-count scales. Software 101 in FIGS. 1-1—1-4 works reasonably wellwith 8-bit A/D converters, but a 10-bit A/D, available from MCU's likethe Mitsubishi M37515 in FIGS. 3A and B, considerably enhances thereliability and accuracy of software 101. The granularity available fromthe A/D hardware should be considered, as 10-12 bit A/Ds will enhancethe points available. Note, for example, that the resistive values thatdistinguish Identifiers LL⁰, Ll¹, LL², and LL³ in FIG. 20 are quitesmall. It is advisable to opt for the maximum number of bits availablefrom an A/D converter.

Rounding Up

The accuracy of the final power supply Vout value calculated by software101 in FIGS. 1-1—1-4 is only as valid as a configurable power supply'sability to deliver precise voltages. The representative configurablepower supply 122 in FIGS. 4-1 and 4-2 provides a resistor ladder 160which is only capable of voltage adjustments in 0.375 VDC increments.This restriction is accounted for by always “rounding up” software 101'sfinal voltage value to the next higher available voltage from aconfigurable power supply 122. A power supply that offers more granularvoltages can be built, so that software 101 can be more accurate, if theapplication requires.

Power supply 122 in FIGS. 4-1 and 4-2 has a minor anomaly in its SHUTDOWN mode. The LT1339 requires a minor modification to its shut downcircuit. Consult the data sheets on this IC available from LinearTechnologies (Sunnyvale, Calif.). Power supply 122 in FIGS. 4-1 and 4-2should also have a small load (100Ω) strapped across the output lines,since the power supply works best when under a minor load.

In principal, software processes defined in software 101 in FIGS.1-1—1-4 should always opt for higher, rather than lower, Vout valueswhen configuring a power supply. Battery voltage ranges between Vmax andVmin are typically substantial. As long as the calculated value of Voutthat is used to configure a power supply is not in excess of a powereddevice's voltage tolerances, there is little concern about delivering anover-voltage power signal to a powered device.

Look-up Tables

Look-up tables can be used to assist in verifying software 101'scalculation results. FIG. 15, as previously noted, illustrates a look-uptable of battery pack voltages. This table can be used to compare Vmaxand Vmin values, to see if a specific battery pack's cell configurationexhibits comparable minimum and maximum voltages. A nearly depletedbattery pack can, indeed, cause false errors. Further look-up tablesthat define the same voltage matrix as FIG. 15, but which show batterypacks in various states of discharge, would clarify Vmin mismatches.

Another look-up table (not shown) can be created to provide a voltagetemplate which indicates typical battery voltage and current parametersfor specific classes of powered devices. As a non-limiting example, alook-up table that delineates the power signal parameters of cellularphones, and differentiates them from parameters for laptop computers,can prove helpful. This could be beneficial, in an example of an airlinethat may allow the owners of laptop computers to use the aircraft'spower-delivery system at each seat, but prohibit power use for cellularphone operations. A simple look-up table can be created that templatesthe two types of devices, as defined by each one's unique powerparameters (Vmax, Vmin, and current-load). Should a passenger connect acellular phone to the power system, software 101, by referencing such alook-up table, would not activate its associated power supply.

“Power Signatures”

Look-up tables (not shown) can contain templated information that linkvoltage and load, as a function of time and “events.” Such a look-uptable provides a “power signature” template for a defined and documentedclass of powered devices. A non-limiting example of a “power signature”can be a voltage and current profile of laptop computers. Thispower-signature table plots anticipated load values as a template. Sucha template resembles FIG. 19, where the BIOS POST of a generic laptoptracks changes in load over time (as the basis of identifying a laptopas distinct from other powered devices that can attach to an embeddedpower system).

The boot sequence of a laptop computer is unique to that type of powereddevice. Because the BIOS boot sequence has been historically aregimented process, the BIOS POST lends itself to a template. A BIOSPOST template (FIG. 19) can serve as an effective means ofdistinguishing a laptop connected to a power assembly 100 like that inFIG. 2. Software 100 written to capture real-time power-load data canaccess a “power signature” template in a look-up table, and match asequence of changes in current (load) to a generic (or specific) powersignature template.

The BIOS POST

Battery-powered devices turn on in ways that are usually very specificto the type of device. Obviously, a camcorder turns off differently thandoes a portable radio. Laptop computers are no exception. If ahigh-sample-rate capture-scope is attached to the input power lines of alaptop, a distinct current-based power signature can be acquired as eachof the sub-systems within the laptop turns on in sequence. This sequenceis referred to as the BIOS POST. It is a complex sequence of hardwarechecks, done at three levels: Early, Late and System Initialization. Forpurposes of the look-up table being discussed here, the only events thatoccur during the BIOS POST are the ones which generate large andreadily-discernible changes in the total load of the laptop. Theseevents typically include the CPU turning on, the display screen(including backlighting), the floppy drive test, and the hard drivetest. The BIOS (and CMOS) initialize each of these hardware sub-systemsevery time a laptop boots. Note: Many of the traditional hardware BIOSfunctions have moved to the operating system, but the net effect whenmonitoring load will still resemble the boot sequence depicted in FIG.19.

Detailed descriptions of various implementations of the BIOS POST areavailable from The BIOS Companion, by Phil Croucher. Electrocution, P.O.Box 52083, Winnipeg, MB, Canada R2M 5P9.

It is not necessary to treat each of these hardware devices as anidentifiable power event related to a specific hardware sub-system. Moreimportant is the sequencing of a series of devices. Knowing whichspecific device turns on or off is relatively unimportant inconstructing a power signature look-up table or template. It is thepattern that is essential, and not specifically which hardware devicesin the laptop are causing the noticeable changes in load being detectedon the powerlines.

FIG. 19 is a graphical representation of a hypothetical BIOS POST. Eachspike in electrical current, logged over time, represents an eventwithin the BIOS POST sequence. Note that the events are not linkedspecifically to an actual sub-system operation. Which device turned onand off is irrelevant. The fact that a defined sequence of on/off events(in a context of other measurable power events) can be identified, leadsto a reliable power signature template. As technology changes occur insuch powered devices as laptop computers, the representative generictemplate FIG. 19 represents will change. The important issue is that alllaptops will change accordingly, so the purpose of a table such as thatshown in FIG. 19 will still be served—to differentiate a certain classof powered devices, (e.g., laptop computers) from other classes ofelectronic goods (e.g., cellular phones).

As with any other power monitoring function, a high-bit-rate A/Dconverter will yield more granular power-signature templates.

Databases

Database creation can be part of the processes of software 101 in FIGS.1-1—1-4. Flowchart 101 indicates a number of instances where acquired orcalculated values are stored (e.g., step 624). Some of the stored valuesare transient (e.g., step 658), and only relevant to software processesspecific to a particular powered device and its battery pack. Otherstored values have long-term (or historical) relevance. For example,while not shown here, software 101 can be configured to permanently logthe final Vout value in step 795. This is relevant, should a user allegethat hardware assembly 100 in FIG. 2 (and its related software)delivered an incorrect voltage to the user's powered device, whichconsequently caused damage.

Software 101 can be modified to run sub-routines which log userinformation, such as number of users who have accessed the software,number of users who did not complete the sequence of required connector132 attachments (see FIGS. 6-6C), the number of errors generated, thenumber of Vmin (or Vmax) readings that fell outside existing look-uptables, etc.

Data which has value to owners of software 101 (and its relatedhardware) can include the parameters expressed in the “Power Monitor”screen display in FIG. 18. Displayed information includes a powersupply's Vout (556), a match of a known battery pack manufacturer'sdesign voltage (562), position of connector 132 (560), LED warninglights or active indicators (568), whether a powered device's battery isbeing charged (564), power consumption expressed as Amps (558), andother data relating to the activities at a particular power outlet.

The “Power Monitor” GUI displays relevant data to eitherowners/providers of hardware/software for power delivery. Such anowner/provider may be, for example, and airline which offers power ateach passenger seat. Logging such information from “Power Monitor”software can prove beneficial in analyzing the amount of fuel burned todeliver electrical power to passengers. Detection of battery charging isalso relevant, when an airline elects not to allow battery charging onits flights. Power Monitor then becomes a “policing” agent which can, insoftware 101, be configured to automatically shut down its power supplyif battery charging is detected. The proper use of connector 132disables battery charging when connector 132 is in the position shown inFIG. 6C, so knowing that connector 132 is being used properly can bevital information that gets logged in a database.

A Simple Version of Software 101

Software flowchart 101 in FIGS. 1-1—1-4 offers a sophisticated method ofnot only calculating a valid Vout value for a configurable power supply,but of recognizing various positions of a connector, and determining themanufacturer's design voltage of a battery pack, among other functions.In many applications, software 101 can be reduced to a very simple, yeteffective algorithm that delivers a useable Vout value.

The following steps are all that are required:

-   -   1). Sample battery Vmax    -   2). Sample battery Vmin    -   3). Vmax+Vmin÷2=Vout

This will work in most applications, but at the sacrifice of someprecision, and the loss of viable values that can be used for databases.The hardware required for this minimal software does not require anyreconfigurable connectors. Instead, a controllable powerline switch suchas that shown in FIG. 13A as 526 is required. Such simple software isalso suitable for basic devices like that shown in FIG. 7.

FIGS. 13 (and 13A schematically) show a manually-selectable powerconverter. Connector 508 in FIG. 13A is representative of a typeillustrated in FIGS. 6-6C, 6 D, and 8. The three-step algorithm aboveoperates with a control of a switch 526. Additionally, LED 402 issoftware controlled so that it illuminates only when calculated Vout instep 3 above is matched at the manual voltage selector 504. If thecalculated Vout from step 3 above is between selector voltage tick marks(e.g., 16 volts is the calculated Vout, but selector dial 337 offersonly 15 or 17 volts), the higher voltage should prevail.

As described in the “Hardware” section, a basic voltage-comparator canalso be used in assembly 400.

Software

Hardware

Software flowchart 101 in FIGS. 1-1—1-4 operates with embeddedpower-delivery hardware. FIG. 2 illustrates a representational diagramof an embedded controllable-output-voltage power supply 122 and relatedhardware that is enabled by software 101, as a means of determining Voutof a powered device 136. Power module 100 executes software 101 using aninterface provided by a connector 132 (see FIGS. 6-6E, and FIG. 8)attached to a powered device 136's battery pack 134. A user manipulatesconnector 132 so that software 101 (and MCU 102 ) can acquire voltagevalues from a battery 134. Software 101 then uses those voltage values,in conjunction with look-up tables (see FIGS. 15, 17 and 20 ), toconfigure a power supply 122. Software 101 is also capable of monitoringall user activities by using various data-acquisition processes. A fulldiscussion of related hardware appears in the “Hardware” section.

The following description of software 101 (FIGS. 1-1—1-4) detailsstep-by-step processes. These should be read in conjunction with theinformation presented in companion-section “Software For In-Line, CordedPower-Delivery Hardware.” The flowchart for in-line hardware powerdevices appears in FIGS. 1A-1—1A-9 as software 800. That sectiondiscusses general operational concepts, specifics of connectors andrelated hardware. Note that In-Line hardware does differ from embeddedpower-delivery hardware. As a non-limiting example, a cordedpower-conversion module can use a manually-configurable voltageselector, while its embedded counterpart would not have any manualcontrols. Therefore, differences between embedded and in-line powerhardware should be taken into account when reading these companionsoftware descriptions. Neither software 101, nor software 800, islimited to use only with the hardware devices referenced herein. In manyapplications, software 101 and 800 are totally interchangeable.

Two Software Versions

Software flowchart 101 in FIGS. 1-1—1-4 is a slightly abbreviatedversion of flowchart 800 in FIGS. 1A-1—1A-9. Repetitive sequences insoftware 800 often are minimized in software flowchart 101, for example.Such sequences are fully described in software flowchart 800. Flowchart101 and 800 are meant to be examined together.

Also, while both flowcharts describe the same basic processes andachieve the same functions, each presents a slightly different approach.The order of some processes are re-arranged, for example. This does notdetract from functionality or performance, because the processes are notregimented, and can be restructured (to some degree) withoutjeopardizing the integrity of the software. For example, output-voltagecan be calculated prior to, or after, a user's reinsertion of aconnector 132 (FIGS. 6-6E). Specific sequences of user's manipulation ofa connector 132 can be missed, perhaps because a user jumped ahead andinserted a connector 132 into its battery pack. Neither software 101(FIGS. 1-1—1-4), nor software 800 (FIGS. 1A-1—1A-9) require all steps torun.

Software Operation

One set of connector 103's pins (FIG. 2) provides a discreteshort-to-ground used only by an in-line power adapter. A second set ofpins at connector 103 is reserved for an adapter-less power-cord 115.Software flowchart 101 describes this second sequence, withtwo-conductor cord 115 connecting power supply 122 (in power module 100)to battery 134 (and its associated powered device 136).

The primary difference between software 101 (FIGS. 1-1—1-4), andsoftware 800 (FIGS. 1A-1—1A-9) is that software 101 is designed to runon embedded hardware, while software 800 is tailored to operate withexternal power hardware, such as an in-line corded DC/DC (or AC/DC)power conversion adapter.

Embedded power hardware for software 101, as depicted in a block diagramas FIG. 2, is typically connected to a powered device 136 via a simpletwo-conductor power cord 115. A previously referenced example of anembedded hardware application is to embed a power module 100 behind thedashboard of a car, so that it can deliver power through thecigarette-lighter outlet (element 103 in FIG. 2). With a module 100behind the dashboard, the configurable power supply 122 can change itsVout to match the Vin of a powered device 136. This ability for a module100 to auto-configure its power output eliminates the need to use thein-line DC/DC converter typically associated with powering a device 136from a car's cigarette-lighter power port.

The hardware of the invention is also available as an external, in-lineDC/DC (or AC/DC) converter adapter, as in FIGS. 10, 11, and 13. Thistype of hardware operates with software 800 (FIGS. 1A-1—1A-9), whichprincipally differentiates itself from software 101 (FIGS. 1-1—1-4) byits ability to operate with a variety of input power sources. Anotherdifferentiator is that the external power-conversion adapters allow forboth a user-adjustable, or an auto-configuring, output voltage.

As shown in FIG. 2, power module 100 is compatible with a variety ofexternal power-conversion adapters (FIGS. 10, 11, 13, anddiagrammatically depicted in FIG. 13A). Assembly 400A typifies aninterchangeable alternative to the simple two-conductor cord 115 (andassociated connector 132). A user can select either of these two meansof delivering power from a module 100 to a powered device 136. Powermodule 100, and power-conversion adapter 400A, are compatible, andoperate together to optimize the final output power to a powered device136 (See discussion of power box 400 in FIG. 13A).

Connector 103 in FIG. 2 is a nine-conductor (two power, and seven datalines) interface. This style of connector is identified as an “ARINC628” style connector available from Hypertronics (Hudson, Mass.). Ituses two discrete non-power pins to create a short-to-ground when thetwo mating elements of the connector are attached. This is a commonlyused method of determining when a connection is made, and is readilyknown to those skilled in the art. Software flowchart 101, in step 602,identifies the short-to-ground, indicating a cord-only connection. Ifthe query in step 602 were FALSE, and input powerline #2 is active,software step 604 executes, since the FALSE report indicates that anexternal power conversion adapter 400 A (FIG. 2) is connected to powermodule 100. This FALSE value results in a 5 VDC output from power supply122. This 5-volt power signal provides power to an attached in-linepower adapter. The description of software flowchart 800 (FIGS.1A-1—1A-9) addresses how an in-line power adapter utilizes this 5-voltpower delivery from embedded power module 100.

This is the only reference to a second series of software processes thatare specific to an in-line power adapter. Further information about theparticipation of software 101, and its embedded hardware, in the in-lineadapter functions is detailed in the description of software 800 (FIGS.1A-1—1A-9).

An Oft-Repeated Sequence

One of the basic building blocks of software 101 in FIGS. 1-1—1-4 is asimple powerline voltage acquisition, followed by sampling load on thepowerlines. This two-sequence process is so central to the operation ofsoftware 101 that it is highlighted in box 606.

Step 608 samples powerlines 114 and 116 in FIG. 2 identified in softwareas port #1 (there are multiple A/D ports at MCU 102 in FIG. 2A). Thereare specific hardware states that can be identified by a voltage checkof powerlines 114 and 116. One hardware state is whether a connector 132(see FIG. 6B) is inserted in its Position #1. If connector 132 isinserted as shown in FIG. 6B (but not 6C), battery 182 will deliverpower along powerlines 114 and 116. Software 101 uses this voltageindicator at A/D port 110 (FIG. 2A) to verify the position of aconnector 132, as well as to acquire battery-voltage informationnecessary to configure power supply 122's output voltage.

Voltage Query

Software 101 uses a voltage detection query in step 610. If thisstatement is TRUE, step 612 executes a GOTO command which puts software101 at step 648—connector 132 is in the configuration shown in FIG. 6B.This event could happen because a user attached connector 132 to batterypack 134 before attaching power cord 115's connector 103 to embeddedpower module 100 (FIG. 2).

If the statement in step 610 of software 101 is FALSE, i.e., there is novoltage detected on powerlines 115 in FIG. 2, then software 101configures power supply 122 to a low output voltage, here 3 VDC. Thislow voltage is applied to power cord 115, in preparation for acquiring acurrent sample (load activity). Load parameters are detailed in the“Identifiers” column of look-up table 990 (FIG. 20). The resistivevalues associated with the “Identifiers” enables software 101 (andsoftware 800 (FIGS. 1A-1-1A-9) to determine specific user activitiesrelating to connector 132, power cord 115, battery 134, and powereddevice 136. At the time of manufacture, all associated hardware devices(e.g., power cords, connectors, etc.) are pre-configured to operate atspecific resistive values. Software 101 compares each line-load valueacquired in the steps of the flowchart in FIGS. 1-1-1-4 to look-up table990. These comparisons of line load to pre-determined hardware resistivevalues determines the particular combination of hardware elementsattached to the power delivery hardware. Also, matching load values tolook-up 990 determines which of three possible positions a connector 132is in at any given time.

Load Sampling

Once a low-voltage is applied to the powerlines in step 614 of software101 (FIGS. 1-1-1-4), a quick line-voltage check (step 620) is performedto make sure that power supply 122 (FIG. 2) is properly configured. Thispower supply output-voltage sequence (steps 614-620) is performed onlyonce, prior to the first time that a powerline load sampling is done. Ifthe answer to query 620 is FALSE, step 618 executes a fill shut down(618) of power supply 122 in FIG. 2. Failure of power supply 122 toproperly execute a voltage command is considered a critical error.

In step 622, software 101 makes a call to MCU 102 (FIG. 2) to sampleline load at A/D I/O port #3 (lines 106 in FIG. 2A). This port isconfigured to read electrical current directly using a resistive element108. The acquired load value is stored in memory (step 624) as anOhm-value labeled as “LL^(A)”, then this value is compared in a look-uptable (steps 626 and 628 ). Look-up Table 990 (FIG. 20) serves as thelist of valid comparators to which is compared the resistive-load valueacquired in steps 622-626. The results of the look-up table comparisonis presented in step 630. Step 632 reduces the look-up comparison to asimple query: “Does LL^(A)=LL³?” In the look-up table, LL³ defines anOhm-value that equates to a power cord 115 and connector 132 in a finalconfiguration that is ready to be attached to a battery pack. Note thatthe resistive Ohm values in look-up table 990 can be converted to actualcurrent values @ 3 VDC.

Look-up table 990 (FIG. 20) is expressed as resistive values, in Ohms.This is because Ohm values are more suitable to the hardwaredescriptions in look-up table 990. Since the line voltage is known formost of these expressions, these Ohm values can be converted tomilliamps or other suitable electrical current expressions to minimizecomputational activity during line-load samplings As powerline voltagecan vary after step 760, where power supply 122 (FIG. 2) is turned on,all values expressed as direct current readings should be recalculated,and look-up table 990 updated accordingly

If the comparator test in step 632 is FALSE, step 634 initiates a userprompt that is intended to promote compliance with the expected hardwarestate. The expected hardware state here is that power cord 115, andconnector 132 are attached. If connector 132 features a protective cap530 (FIG. 6D), it is supposed to be removed. Note that the error-loopgoes back to step 608, where a line-voltage check is again performed. Nolow-voltage power is ever applied to powerlines 115 (see step 614),without a check to see if the powerlines are available, or if there isalready a voltage present from a battery pack 134. If there is a voltagepresent on the powerlines, the hardware is in a state of having a powercord 115 and a connector 132 already properly inserted in a battery 134.There is only one hardware combination that will allow battery voltageto flow on he powerlines . . . it is LL⁵ (see Look-up Table 990 in FIG.20).

Assuming that test 632 returns a value of TRUE, the final step insequence 606 of software 101 (FIGS. 1-1-1-4) is to reconfigure theoutput of controllable power supply 122 (FIG. 2) to 0 VDC, i.e., shutdown. This frees the powerlines for further line-voltage samplings.

Multiple Queries

The abbreviated format of software flowchart 101 in FIGS. 1-1-1-4condenses a series of line load data acquisition and comparisonprocesses. The notation in step 636 indicates other “LL?” (Line Load)queries. These are defined in detail in the description of softwareflowchart 800 (FIGS. 1-1-1-4A).

Objective

While oversimplified, software 101 uses hardware that functions as theequivalent of a multi-meter to discern what is happening in itsenvironment. By reading voltage and current, software 101 is able torespond to events in a meaningful way. Monitoring hardware by readingline voltage and current (line load) enables software 101 to prompt auser to configure various hardware elements in a specific sequence. Byperforming these functions in software, the need for a user to knowanything about the power requirements of a host device is eliminated.Thus, software 101 and related hardware provide a system for determiningthe power requirements of a previously unknown battery-powered device.

Repetitive Loops

Software flowchart 101 in FIGS. 1-1-1-4 only shows a single execution ofeach process sequence, such as one voltage and load sampling in box 606.In reality, software 101 is constantly looping through repetitivevoltage and current samplings. No functions, such as turning on powersupply 122 (FIG. 2), are executed without first checking line voltageand current to make sure that all hardware elements are properlyconfigured. More importantly, since a user is involved in all processes,software 101 repeats voltage and load samplings to make sure that a userhasn't performed some action while repositioning a connector 132 thatcreates an error state. Therefore software 101 performs continuoussamplings to assure that all machine states are as they should be. Dataacquisition sampling rates, while not specified here, should be timedbased on the critical nature of a user's actions at any given stage insoftware 101's progression.

Once Connected

Step 640 in software flowchart 101 (FIGS. 1-1-1-4) assumes that a powercord 115 and connector 132 (FIG. 2) have been configured to be compliantwith “Identifier” LL³ in look-up table 990 (FIG. 20).

Again, a line-voltage check in steps 642-644 detects a voltage onpowerlines 115, confirming that connector 132 has been properly insertedinto battery 134. A TRUE answer to the query in step 644 confirms the“Battery Connected” state in step 648. Note: References to “Red” and“Green” in flowchart 101 (FIGS. 1-1-1-4) correspond to “Position #1”“Red,” and “Position #2” =“Green” of a connector 132 (see FIGS. 6-6C).

MCU 102 in FIG. 2 is configured to be able to acquire both positive andnegative voltage values. This is likely not necessary, since allelements of the power system, including the power cord, and allconnectors are manufactured to be mating components. However, MCU 102does have the ability, if necessary, to reverse the polarity of thepowerlines. A power switch 112A in module 100 is needed to performpolarity reversal. Software 800 (FIGS. 1A-1-1A-9) does not detailpolarity reversing, but, this function is also included in the inclineadapter version, and can easily be integrated into software 101 by oneskilled in the art.

Voltage Acquisition and Calculation

Software 101 acquires voltage values from battery pack 134 (FIG. 2) insteps 656-678. These processes are also detailed in the discussion of“Software For In-Line, Corded Power Delivery Hardware.”

Of note is A/D I/O Port #4, which is. polled in step 670. This portincludes a large resistive load such as a power resistor. The resistivevalue of this load is substantial enough to simulate an operationallevel of a powered device 136 (FIG. 2). The Ohm-value of this load isroughly computed by referencing the “Load Current” expressions in FIGS.15. As can be seen, this supplemental load is based on the charge rate“C” of each type of battery cell chemistry.

There is no need to perform complex computations if a type of powereddevice is known. As a non-limiting example, if the type of anticipatedpowered device is a laptop computer, it can be reasonably assumed thatthe average load drawn by this class of powered devices is 1.0-2.5 Amps(given the state of the art for such devices). The high-end load of 2.5A includes the power required to charge the laptop's battery. Sincesoftware 101 (and 800 ), with associated hardware, are designed todisable battery charging functions, the current-drain is more typicallya maximum of 1.0-1.5 Amps. For purposes of a load figure for A/D I/Oport #4, 750-900 ma is adequate. The purpose of this additional load isto pull down the battery voltage, in order to acquire a minimum voltage(Vmin) value.

All computations and calculations of voltages performed in softwaresteps 678-714 can be executed at any time prior to software step 760which is the software step that performs a first Vout command to powersupply 122. As with many of the software sequences, this sub-routinedoes not have to be executed in the exact order of state changes listedin software flowchart 101 in FIGS. 1-1-1-4 (or in software 800 in FIGS.1A-1-1A-9).

Diode Depression

FIG. 6E shows a modified female connector in a battery pack 134. A diode185 is introduced into the wiring circuit in battery pack 134. Thisdiode will depress any acquired voltage values. Software 101 in FIGS.1-1-1-4 (and 800 in FIGS. 1A-1-1A-9) should be recalibrated to reflectthe voltage loss (approx. 0.3-volts for a typical diode). The diode onlyimpacts voltage values acquired from battery cell(s) 182. Outputvoltages from power supply 122 (FIG. 2) are not impacted by diode 185,because the electrical signal to a powered device does not flow throughdiode 185.

Software 101 (FIGS. 1-1-1-4) and 800 (FIGS. 1A-1-1A-9) are modifiedslightly when diode 185 is involved in battery voltage acquisition.Software already distinguishes two voltage acquisition modes. After avoltage-configuration command is sent to a controllable power supply 122(FIG. 2), software 101 verifies power supply 122's output by samplingline voltage (see steps 614-620 in FIGS. 1-1-1-4, for example). Sincepower supply Vout readings are. not effected by diode 185 in FIG. 6E,software 101 (and 800) these voltage acquisitions as non-compensatedvalues. The differentiator software 101 uses is whether power supply 122is in an ON or OFF state. Therefore, any voltage values that areacquired while power supply 122 is in an OFF state must be voltagescoming from battery 134. Thus, any voltage value acquired during an OFFstate of power supply 122 are mathematically voltage compensated.

The effect of the diode on voltage readings is most pronounced onbattery packs that have been deeply discharged. The spread between theno-load voltage (Vmax) and the load voltage (Vmin) can be quite small inthis scenario. Since the diode is a constant in both the no-load andunder-load samplings, the 0.3-volt loss extends to both values. However,FIGS. 1-1-1-45's pack voltages need to be adjusted, since the diode losscan make it appear that a almost-fully-discharged battery pack is belowit's minimum design voltage.

The voltage configuration commands sent to a configurable power supplysuch as 122 in FIG. 2 (or 122A in FIGS. 1-1-1-43A) must output a valuehigher than the Vmin (under-load) voltage value acquired from batterycell(s) 182. If the power supply voltage is lower than the sustainablevoltage of battery 182, battery 182 will dominate the powerlines and bedelivering power to a powered device 136 (in FIG. 6E). The finalmonitoring loop for line voltage (and current) performed by software 101(repetitive steps 788-798 ) allows the software to readjust and optimizea power supply's Vout (step 797). This process can be modified to usestored values of battery Vmin and Vmax, in order to determine if theVout voltage value of a power supply is sufficiently above the Vmin ofthe battery. This will ensure that the battery isn't intermittentlycoming on line during periods when the output voltage of an externalpower supply sags. Software 800 (FIGS. 1-1-1-4A) illustrates thesesequences in greater detail, in steps 961 through 909.

The inclusion of a “bleed” resistor 185 A in FIG. 6E across diode 185will ameliorate the depressed voltage values. Since both diode 185, andits optional resistor, are electrically removed from the battery circuitwhen connector 132A is removed, there is no degradation of voltage orimpedance by diode 185, or its optional resistor.

For further information on the use of diodes, see the section “DiodeUPS.”

Battery Voltage Look-Up Table

Look-up table 799 in FIGS. 1-1-1-45 lists battery cell-voltage rangesfor commonly-used rechargeable battery chemistries. An observation ofthe voltage values indicates that a number of cell-pack configurations“look” like others. The voltage range of an 8-cell Ni-Cad or NiMH packfall within the same voltage range as an 8-cell Li-Ion (Coke) pack, forexample.

Fortunately, software 101 (FIGS. 1-1-1-4) and software 800 (FIGS.1A-1-1A-9) are not looking at mean or average voltage values—software101 reads voltages that are identifying cell-voltage extremes. Minimumcell-pack voltage (Vmin) and maximum cell-pack voltage (Vmax) varyconsiderably, especially Vmax. An 8-cell Li-Ion (Coke) pack can generatevoltage readings as high as 16.80 VDC, while a similar cell constructfor Ni-Cad or NiMH will only yield a maximum no-load voltage of 10.560VDC.

Note that the maximum cell design voltages shown do not necessarilyreflect the actual no-load output voltage a particular cell type iscapable of producing. An NiMH cell, for example, will read approximately1.46-volts when freshly charged. The 1.320-volt value shown in FIGS.1-1-1-45 is the mathematical E°cell value. This lower voltage is used inthe look-up table as a safety measure. Its use avoids excessively highVout voltage values being delivered to a powered device.

All of the voltage values in look-up table 799 are industry-recognizedcell design parameters. In the real world, battery pack state ofcharge/discharge will shift the voltage readings. Condition of the cellsalso plays a major role in depressing both Vmin and Vmax. Fortunately,the Vmin voltage values are more subject to depression under loadconditions. The test load can be 750-900 ma, which is fairlysubstantial. Cells that are deeply discharged, or suffering from abuseor mistreatment, can be expected to drop precipitously in voltage whenplaced under load. Also, voltage and cell capacity are interrelated.Voltage drops as a function of cell capacity. Compromised cell capacitywill quickly show up as a depressed under-load voltage (Vmin).

At the other extreme, Vmax is a no-load test. The most valid Vmax testwill be one that introduces the least amount of load to the batterypack. Therefore, some attention should be paid to line-load look-uptable 990 in FIG. 20. The lower the total resistive value of LL³, themore effective will be Vmax tests. FIGS. 9A-C show various ways to wirea smart circuit. In light of decreasing overall resistance when readingVmax, the optimum scenario is to wire the cells so that the load of thesmart circuit is eliminated.

Transient cell “recovery” is a characteristic common to all batterychemistries. Cells that have had time to recover from a load event willtemporarily regain increased no-load voltage characteristics. Thus, whenVmax is acquired, for some small amount of time (determined by how longit has been since the battery pack was used), the no-load voltage willread higher than the sustainable cell voltage. That is one reason why aVmax value is acquired first, before the Vmin (load) acquisition (seesteps 660 and 676 in software flowchart 101 in FIGS. 1-1-1-4). This“recovery” characteristic of rechargeable cells is beneficial tocapturing a set of cell voltages that yield a significant spread ofvalues between Vmax and Vmin.

Look-up table 799 in FIG. 15 expresses cell ideals, and is therefore,only a reasonable approximation of reality. But look-up table 799 ishelpful to interpret software 101 (and 800) Vref¹ and Vref² values (seesteps 662 and 682 in software flowchart 101).

A non-Limiting example of the applicability of look-up table 799 (FIG.15) is illustrated using the table below for a battery pack voltage testthat yields a Vmax of 14.00-volts, and a Vmin of 12.00-volts. Consultinglook-up table 799, the following possible voltage matches are available:

Vmin = 12.00 VDC Vmax = 14.00 VDC Li-Ion Ni-Cad NiMH Li-Ion (Coke)(Graphite) Li-Polymer  12.5/12.99  12.5/13.20 10.00/16.80 14.40/16.4012.0/16.80 (10 cell) (10 cell) (4 cell) (4 cell) (4 cell) 15.00/15.5915.00/15.84  7.50/12.60 10.80/12.30  9.0/12.60 (12 cell) (12 cell) (6cell) (6 cell) (3 cell) 10.00/16.80 14.40/16.40 12.0/16.80 (8 cell) (8cell) (8 cell)  9.0/12.60 (6 cell)

Note that the Vmin 12-volt, and Vmax 14.00-volt parameters each fits atleast one of all of the above voltage ranges. However, only the fourbattery packs shown in bold fit both acquired voltage parameters. Sincethe Li-Ion Coke and Polymer 4-cell packs and 8-cell packs only differ inthe capacity of each pack (see footnote 15), these can be considered thesame. Therefore, only one valid voltage-range match of a battery cell'schemistry is achieved by implementing software 101's Vref¹ and Vref²calculations. The 12-cell Ni-Cad and NiMH packs are included because theminimum cell voltage of these packs can be as low as 12.00-volts.

The result of software 101's SORT and LIST steps 706 and 708 is asfollows:

-   -   Vref¹=10.00 volts    -   Vmin=12.00 volts    -   Vmax=14.00 volts    -   Vref²=16.80 volts        Cell Impedance

While not addressed in look-up table 799 (FIG. 15), battery cellimpedance can be a valid indicator of cell type. All cells increaseimpedance as a function of discharge. As such, decreases in voltage arerelated to changes in battery discharge levels. So too, do impedancechanges reflect battery discharge states. These changes in voltage andimpedance aren't very pronounced in Ni-Cad and NiMH cell chemistries,but Li-Ion cells do show clearly defined impedance changes that trackwith decreases in voltage. Impedance checks can be integrated intosoftware 101 or 800, if further granularity in identifying a batterypack's discharge state is required. Such added complexity is usuallyunwarranted, since it will only come into play when the Vmin and Vmaxreadings are from a deeply discharged battery pack. A deeply dischargedpack can result in only a minimal voltage spread between Vmin and Vmax,but cell “recovery” characteristics typically preclude that. Even then,battery and powered device circuits are designed to allow a sufficientbattery reserve that Vmin and Vmax will still be reliable indicators. Donot use impedance testing if diode 185 in FIG. 6E is implemented, or ifa smart circuit is wired into the powerlines, as shown in FIGS. 9A andB.

Connector Removal

Software 101 (FIGS. 1-1-1-4) then moves to a new machine state in step716, with a user prompt to remove a connector 132 already in Position #1(FIGS. 6B and 17) from its battery pack 134 (FIG. 2). Steps 718-720verify that line voltage has dropped to 0 VDC, indicating that connector132 has been removed from battery pack 134. Further validation of thepresence or absence of connector 132 is achieved in steps 722-736, whichis the previously-described line-load test. In step 736, software 101anticipates that the cord/connector combination has reported back an Ohmvalue that matches LL³ in look-up table 990 (FIG. 20), i.e., maleconnector 132 is removed from its associated battery pack 134. If theresponse to the query in step 736 is FALSE, software 101 loops back tostep 716, first generating a user prompt 734 to remind user to removeconnector 132. These prompts are not always available, in which casesoftware 101 continuously loops through the voltage and line loadsampling steps 716-736, until the answer to the test in step 736 becameTRUE (YES).

Step 732 can be configured in software 101 to return an actual value,instead of the specific LL^(F)=LL³ query shown. Thus, the results of alook-up table matching in step 730 can be any one of the pre-defined“Identifiers” in table 990 (FIG. 20). For example, the Ohm-value matchvalue can be reported as an actual value LL², instead of NOT A MATCH toLL³. Thus configured, software 101 can execute an appropriate userprompt 734 that matches the LL² hardware configuration detected. Byreturning the appropriate value (e.g., LL⁰, LL¹, LL², etc.) the userprompt can be better suited to the machine state at that time.

Look-up table 990's value LL² indicates, for example, that a power cord115, and connector 132 are attached (see FIG. 2), but thatresistor-equipped connector cap 540 in FIG. 6D is in place. A userprompt would indicate a need to remove connector cap 540. Obviously,connector 132 is removed from battery back 134, since it would beimpossible to reattach connector cap 540 while connector 132 is insertedin battery pack 134. The response for software 101's sequence of steps716-736 would be FALSE, because a user has put some hardware elementsinto an unexpected non-compliant state by reattaching connector cap 540to its connector. In software 800, as defined in FIGS. 1A-1-1A-9, theentire sequence of various hardware states is detailed. Software 800loops back to the appropriate sequence (steps 823-835 ) to issue a userprompt associated with a reported value of LL² (user prompt 834).Software 101 can be similarly configured.

Connector Reinsertion

Steps 738-758 indicate a new machine state, with connector 132 to bereinserted in battery pack 134 with its green side (Position #2 in FIG.17) upward (FIG. 2). FIG. 6C shows connector 132 in Position #2. Again,a powerline voltage check 740-742 is performed prior to a line loadsampling 744-754.

Note that the response to step 742's question “Vin Detected?” can differin the anticipated TRUE/FALSE response at any voltage check in theflowchart. The TRUE answer is NO, and the FALSE (error response) is YESin step 742 (and also, for example, to the same question in step 720).Software 101 does not want to see a line voltage in this softwaresequence. In voltage verification steps 644 and 674, for example, theTRUE response is YES, and the FALSE response is NO. Steps 644 and 674expect a line voltage to be present.

Power Delivery Sequence

Software 101 (FIGS. 1-1-1-4), in steps 760-798, addresses the finalconfiguration of power supply 122's output voltage (see FIG. 2), andpower delivery to a powered device 136. Step 714 has already defined themost probable (and safest) output voltage for a power supply 122 (FIG.2). A second possible output voltage “Vavr” (Average Voltage) is alsoavailable from step 712. Software 800 details additional steps taken todetermine a “Vbst,” (Best Voltage).

Power supply 122 is turned on in software step 762. The system state, atthis juncture, is that powered device 136 has not yet been turned ON.Software 101 executes an output-voltage confirmation in steps 764-768.Note that MCU 102's A/D I/O port #1 (110 in FIG. 2A) is polled toacquire line voltage. If the commanded Vout value in step 760 matchesthe acquired line voltage in step 764, a TRUE value (YES) is reported instep 768. If the two voltage values do not match, an error loop 770occurs, and software 101 tries to reconfigure power supply 132. If thisloop fails after three attempts, a critical error occurs and powersupply 132 is totally shut down.

Step 772 acquires a powerline load value LL^(H). This line load needs tobe converted to a value that reflects the new Vout from steps 760-768.This is a calculated value, using previously stored line load valueLL^(G) from step 148, multiplied by the value of Vout (from step 760).The result becomes new voltage-adjusted value LL^(H) in step 776. Thenew load value is stored in memory as LL⁶, and is made available inlook-up table 990 (FIG. 20). A verification is made on the loadcalculation in step 778, to confirm that acquired load value LL⁶ is thesame as calculated value LL^(H).

Steps 780-785 is a sequence of powerline voltage acquisitions. Thissequence differs from previous line-voltage acquisition activities. Thisset of two voltage values is specific to determining possible changes inoutput voltage commands to power supply 122. Step 780 acquires a no-loadvoltage (Vnol), which is stored in memory (step 781). Then, a load atA/D I/O port #4 (106 in FIG. 2A) is introduced into the circuit, in step782. The resistive load available at port #4 is substantial, beingwithin a range of 750-900 ma. A second voltage is acquired as Vlod, butthis value is voltage under load (783). The additional 750-900 ma drainon the powerlines roughly simulates the operational power requirementsof a powered device 136 (FIG. 2).

The two stored voltage values Vnol (a no-load voltage stored in step781), and Vlod (an underload voltage stored in step 784) are compared instep 785. If the two voltage values are within a tolerance of 5% to eachother, no output voltage adjustments are made to power supply 122.However, if there is more than a 5% deviation between the load (Vlod)and no-load (Vnol) voltages, a voltage adjustment is commanded in step786. This helps to avoid voltage sags that could occur when the powereddevice turns on. Software 101 uses this basic approach to assure that apower supply 122's (FIG. 2) output voltage does not drop below the Voutvalue of Vmin when the load of the powered device is induced in thesystem (i.e., when the powered device is turned on).

Powered Device is Turned ON

Software 101 (FIG. 1) concludes in steps 787-798. Step 787 prompts auser to turn on powered device 136 (FIG. 2). Software 101 samplespowerline load (step 788) to determine whether this user action hashappened. The load value will likely be expressed as any increase incurrent above previously defined load value LL⁶ from step 776 (andavailable in look-up table 990 (FIG. 20). This new line load value LL¹has stored in step 789 as LL⁷, and is compared to LL⁶ in step 790.

The timing of line load sampling steps 788-790 is relevant. If, as anon-limiting example, a powered device 136 in FIG. 2 is a laptopcomputer, a BIOS POST sequence will occur within a window of the first5-30 seconds after a user turns on device 136 (the time at which theBIOS POST occurs can vary from laptop to laptop). FIG. 19 illustrates aBIOS POST event. Hardware devices within a powered device are turned ONand OFF during this activity, so it would be appropriate to sample lineload during this 8 seconds of intense activity. The large spikes incurrent draw are easily detectable as confirmation that the powereddevice is activated. A template of a BIOS POST in FIGS. 1-1-1-49 can beimplemented in software 101, which is used to identify the type ofpowered device being powered. Other powered devices, for example aCD-ROM audio player, would not exhibit the characteristic boot sequenceof a laptop computer. This device-class identification process is notcritical to the operation of software 101, or any related hardware.

Once the BIOS POST has completed its hardware testing, a reasonablyrepresentational LL¹ value can be acquired by software 101 in steps791-796.

Steps 791-797 are a repeat of steps 780-786, as previously discussed.Again, this is a voltage-stability check used specifically to assurethat the output voltage of power supply 122 (FIG. 2) does not sag in theactual under-load conditions being created by the powered device 134.

The final sequence 798 in software 101 (FIGS. 1-1-1-4) is a continuousmonitoring of powerline voltage. Software 101 is looking for a powerdisconnect, which would occur when a user removes connector 132 frombattery pack 134 (rig. 2). If a zero-voltage value is detected, software101 immediately commands MCU 102 to shut down power supply 122. This isto ensure that a connector 132 is not powered while its electricalcontacts are exposed to a user.

Software 101 also monitors powerline load during its monitoringsequences 798, sampling current readings and comparing them to Ohmvalues expressed in look-up table 990 (FIG. 20). Any regression toresistive value LL⁶ indicates that a powered device has been turned OFF,but that a connector 132 is still attached to a battery pack 134.Recognizing this OFF state can be useful for power conservation—as powersupply 122 (FIG. 2) can be put into a standby or sleep mode. If powersupply 122 is put into such a wait mode, software 101 retains its lastVout value, should a user turn the powered device back ON. However, if apowered device is turned OFF, and connector 132 isremoved from batterypack 134, power supply 122 is shut down. If a user reconnects the samepowered device, software 101 executes again, in its entirety.

Software for In-Line, Corded Power-Delivery Hardware

Note: Matter presented in this section is often also described in theprevious software sections, as well as throughout the hardware sections.Any relevant matter is assumed to be included here by reference, as ifit were presented here in full.

Hardware

FIGS. 1A-1-1-9 illustrate software 800 that operates primarily withexternal power conversion adapter hardware, a non-limiting example ofwhich is device 335B in FIGS. 13 and 13-1 (and shown diagrammatically as400 in FIG. 13A), or equivalent external power adapters. The hardware iscomprised of manually-selectable output-voltage indicator 337,configurable DC/DC (or AC/DC) power converter 122A, blink/solid LEDindicator 402, powerline switch 526, and a source of logic, controllerand data acquisition, such as microcontroller (MCU) 102A.

In operation, a user manipulates voltage selector 504 in selectableindicator 337 (FIGS. 13 and 13A). MCU 102A acquires at least one voltagefrom a battery 508B of an associated powered device 508C that isattached at output connector 508. The attachment is via a connector 132(reference FIGS. 6-6D), and a power cord 508A.

At least one acquired, or processor calculated, voltage value is storedin MCU 102A's memory 518A as a value which, when matched at selectorindicator 337, serves as a confirmation that a user has properlyconfigured voltage selector 504. When a voltage match is confirmed, MCU102A locks out voltage selector 337 from any further inputs, and alsoilluminates LED 402 to confirm to a user that power adapter 400 isproperly configured.

LED 402 can illuminate in a non-limiting number of ways, such asblinking, solid ON/OFF, or by changing color. The rate of blink will beused herein as a non-limiting example of how LED 402 operates. Rate ofblink slows as voltage selector 504 moves away from the target voltageto be matched and, conversely, LED blink rate accelerates as voltageselector 504 is rotated toward the desired voltage. When an acceptablevoltage match is achieved, LED 402 stays solid ON in this example.

Once selector 337 (FIG. 13A) is properly configured, MCU 102A configurespower converter 122A to output the desired voltage. Next the MCUverifies, at conductors 527 and 529, that the output voltage is correct,then MCU 102A closes powerline switch 526, allowing power to flow topowered device 508C.

Power converter 122A can also be an AC-input/DC-output power converter(or even a DC-to-AC inverter). Those skilled in the art can make changesto software 800 (FIGS. 1A-1-1A-9) to provide compatibility andoperability with AC power. Some features of power box 400 (FIGS.1-1-1-43A) and software 800 do not operate the same, such as the initialvoltage initialization process between a power source and power box 400.

Hardware Variants

Manual voltage selector 337 is not essential to the operation ofconfigurable power adapter 335B in FIGS. 13 and 13-1 (diagrammaticallydevice 400 in FIGS. 1-1-1-43A). MCU 102A is capable of automaticallyconfiguring power converter 122A without any user intervention. Thiswould be a preferred mode for delivering a matched voltage to a powereddevice.

An alternative modality uses a simple voltage comparator circuit tomatch a voltage input from a battery source 508B (FIGS. 13A) to anoutput voltage of a power converter 122A. The battery voltage value inthe comparison is Vmax (no-load voltage). The actual output of a powerconverter 122A (Vout) would be depressed by 10% of Vmax or, a moresimple approach, would be expressed as:Vmax−1 volt=Vout

An LED 402 is used to indicate a successful voltage match. A gated FETserves as a switch 526 to create an electrical path between powerconverted 122A and battery 508B, and the FET also switches the LEDcircuit ON.

FIG. 11 shows a variant, with an intermediate power conversion box 357that is inserted in-line between a manually configurable power adapter335A and a host device 349's battery pack 355. This configuration ofpower-conversion box 357 is comprised of an MCU 102A (FIG. 13A), an LED338, and a powerline switch 526A (reference switches 526 and 526A inFIG. 13A for equivalents). Power conversion box 357, having acquired atleast one voltage from battery 355, then samples the output voltage ofpower adapter 335A while a user rotates selector 337. Once the outputvoltage from power adapter 335A matches the desired voltage, the MCU inbox 357 illuminates its LED as described above. Powerline switch 526 (or526A) is held closed by MCU 102A as long as the output voltage frompower adapter 335A matches the defined voltage. Should a user rotateselector 337 in FIG. 13A to a position that is not a match, even whilepower adapter 335A (FIG. 11) is in operation, software 800 commands MCU102A to open powerline switch 526 (or 526A), which discontinues power topowered device 508C.

Hybrids

FIG. 10 is essentially the same as FIG. 11, except that power conversionbox 357 in FIG. 11 has been integrated in battery housing 347 in FIG.10. Battery housing 347 can be an empty plastic shell, or have some (orall) of its battery cells removed. Because migration of MCU 102C, powerswitch 526C, and optional LED 338C to battery 347's enclosure creates adedicated device specific to a mating powered device 349. In the early2,000s, automotive accessory voltage could change to 42 VDC. Whatevervoltage is currently in use is considered relevant here. Whilerestrictive in being dedicated to a particular powered device 349, sucha battery housing assembly 347 eliminates the external power conversionbox 357 shown in FIG. 11.

FIG. 10 shows a laptop computer 349, with a dedicated battery pack 347which contains an MCU 102C that is pre-programmed with the input voltagerequired to properly power laptop 349. In an alternative modality, thepre-programmed voltage information can be expressed as digital data,made available to an external power adapter 335 by means of powerlinemodulation. A modulator/demodulator 339 in battery 347, and itscorresponding MD/DM 339A in power adapter 335, provide a simple, yeteffective means of communicating data between the two devices. Giventhat FIG. 10 includes a battery 347 with a dedicated specific voltage,and that power adapter 335 can adjust its voltage output, powerlinemodulation can occur at a known voltage, which simplifies the operationof the modulators/demodulators 339 and 339A. Those skilled in the artcan readily implement the powerline communications of this modality ofthe invention.

Integrating battery cells into a battery housing 347 in FIG. 10, alongwith one of the electronic assemblies described above, allows a powereddevice 349 to have a battery reserve. Should there be a disruption ofinput power along cord 341, a partial battery would serve as aneffective emergency Uninterruptable Power Supply (UPS). A power switch526C, a diode 185, or a power FET (or equivalents) is used to switchfrom external power to battery power (see FIG. 6E, and related textsection “Diode UPS”).

The use of smaller cell sizes, with lower capacity, provides reasonablepower reserves, as battery back-up. Using smaller cell sizes does notnecessarily translate to reduced battery capacity. For example, the 18mm cells manufactured when Li-Ion was evolving as a battery technologyin 1995-'96 have lower capacity ratings than today's 17 mm (or even 15mm) cell sizes. Also, polymer cells show promise of equaling orexceeding older cylindrical cell capacities. Polymer cells are morespace (volumetrically) efficient than cylindrical cells. Therefore,smaller and more energy-dense cell, and evolving polymer space-savingcell configurations, help to ensure that there be little trade off whenintegrating electronics into existing battery pack enclosures.

Input Power

Input power to power conversion box 400 in FIG. 13A can be either afixed input voltage, or is a power source that can have a configurableoutput voltage, equivalent to that described in FIGS. 2 through 5A. Ifthe input voltage to power box 400 is coming from a fixed voltagesource, MCU 102A in FIG. 13A is wired with its own voltage regulator, sothat MCU 102A is powered as soon as electrical input is available atlines 505 and 507.

If the input voltage is coming from a source of variable voltage thathas its own control capabilities, such as assembly 100 in FIG. 2, powerbox 400 in FIG. 13A “signals” to its controllable input power sourcethat it is functioning. A controllable power source 100 has beenpre-configured with resistive values that are specific to a power box400 (as detailed in the following “Software Operation” section. Insensing these resistive loads, and finding them to match expectedpre-determined values, a controllable input power source 100 deliversvoltages expected by power box 400 at the appropriate time. Thus, asseen in software flowchart 800 in FIGS. 1A-1-1A-9, a +5 VDC power signalis first delivered to power box 400, which powers its MCU 102A only.Once power box 400 has been configured by its user to the correct outputvoltage (as described above) LED 402 changes its state (e.g., turns ON).This indicates a change in the overall load sensed by controllable inputpower source 100, which then increases its power to a pre-determinedvalue. This predetermined voltage value may be 12 VDC (for example, ifpower box 400 is to be used in an automobile), or the output voltage canconfigure to 15, or 28 VDC (as a non-limiting example of which is apower box 400 manufactured to operate at such voltages because itsintended use is on an airplane where such input voltages are common).

An alternative power source is available from which MCU 102A in powerbox 400 (FIG. 13A) can be powered. Battery 508B can power MCU 102A whena user attaches connector 132 to couple battery 508B to power box 400.Note that, in the description of a unique connector 132 in FIGS. 6-6C,the connector must be inserted in the manner shown in FIG. 6B for powerto be available. FIG. 6E, and its associated description in the section“Diode UPS”, define a non-limiting means of configuring the circuitwithin a battery 508B with a diode, so that there is only one positionfor a connector 132. The connector modality in FIG. 6E resolves theissue of a dual-position connector 132, and provides a convenient meansof powering MCU 102A.

Software Operation

Software 800 in FIGS. 1A-1-1A9, in its first state (steps 801-805 ),determines the characteristics of its input power source. Software 800assumes that there is power available as soon as its associated hardware(for example, power box 400 in FIGS. 1-1-1-43A) is connected to a powersource. In the modality shown here, that power source outputs either 5VDC (as detected in software voltage-comparator steps 802-803 ), 15 VDC(in voltage-comparator step 804), or 9-14 VDC (in voltage-comparatorstep 805).

If the detected input voltage is 5 VDC, software 800 is pre-programmedto execute all processes shown in FIGS. 1A-1-1A-9. A 5 VDC-detectedinput voltage is an indication to software 800 that it is connected tospecific matching hardware. Such hardware as exemplified in assembly 100FIG. 2, and its related software 101 in FIGS. 1-1-1-4, are configured toperform interactions with hardware equivalent to 400 in FIG. 13A andsoftware 800. As a non-limiting example of which is that MCU 102A inFIG. 13A performs functions, such as turning on LED 402, that alter theoverall detectable load of hardware 400. Software 101 is configuring itspower converter 122A to output a low voltage (in this non-limitingexample, +5 VDC) from its power converter 122A. Software 101, andrelated hardware 100 as exemplified in FIG. 2, is monitoring the load atinput powerlines 114 and 166 (which are the same as powerlines 505 and507 in FIG. 13A). When LED 402 in FIG. 13A turns on, software 101detects that change in load (the value of which was predetermine at thetime of manufacture of power box 400). Software 101 then changes itsoutput voltage to 28 VDC. Software 800 in FIGS. 1A-1-1A-9, senses thechange in input voltage from +5 VDC to 28 VDC, and switches on DC/DCpower converter 122A in FIG. 13A, via control line(s) 510.

By this non-limiting example, it is seen that software 101 in FIGS.1-1-1-4 performs rudimentary handshakes and acknowledgments withsoftware 800 in FIGS. 1A-1-1A-9. Software 101 responds to load changesat powerlines 114 and 116. Software 800 in FIGS. 1A-1-1A-9 providesdearly defined resistive loads at appropriate times in its processes,which are indicators to software 101 of various states in hardware 400in FIG. 13A.

To simplify this line load-based handshaking, input lines 505 and 507(FIGS. 1-1-1-43A) are switch-isolated (516A) from DC/DC power converter122A. Only MCU 102A is drawing power from the 5-volt input. This alsomeans that any powerline activities downstream of converter 122A are notdetectable by software 101 in FIGS. 1-1-1-4 along powerlines 114 and 116in FIG. 2 (505 and 507 in FIG. 13A). Therefore, a resistor array 509 ispre-configured to induce three specific pre-determined load valuesdetectable by software 101 at powerlines 114 and 116 (505 and 507).Basically, upstream hardware 100 in FIG. 2 (or equivalents) with itssoftware 101, needs only to detect three pre-determined resistive loadvalues. Load value #1 serves as a device ID, which tells hardware 100(and its software 101) that a compatible device 400 is attached. Thishandshake function can also be performed by a simple resistor inconnector 103 (FIG. 2) that attaches a power box 400 in FIG. 13A to ahardware assembly 100 in FIG. 2. The pin outs of connector assembly 103,which provides a means of detecting the presence of a power box 400.

A powerline load value #2, detectable by software 101 in FIGS. 1-1-1-4is used to notify software 101 of the proper time to reconfigure thepower output of its power supply 122 (in FIG. 2). The previous voltageof 5 VDC changes to 28 VDC (or any other pre-determined output voltagedeemed appropriate).

A powerline load value #3, detectable by software 101 in FIGS. 1-1-1-4is used to notify software 101 to shut down its power supply 122. Thisis for critical error states, such as hardware 400 in FIG. 13Aexperiencing over-voltage, over current, excessive thermal activity, orother abnormalities of operation. This shut-down capability is notdefined specifically in software 800 in FIGS. 1A-1-1A-9, but anyoneskilled in the art can readily include such safety checks anderror-reporting states. In such a shut-down condition, software 101defaults to its standby output voltage of 5 VDC. Also, power supply 122will stay in its 5-volt state as long as a connector assembly 103 (FIG.2) remains attached. If software 101, having reconfigured the output ofits power supply 122 in FIG. 2 to the low-voltage (5-volt) standby mode,does not find powerline load values that matches expected values,software 101 executes a total shut down of power supply 122. Not all ofthese functions are detailed in software flowchart 101 in FIGS. 1-1-1-4,nor software flowchart 800 in FIGS. 1A-1-1A-9, but those skilled din theart can easily add such functions to the existing software, usingexisting shut-down processes described in various places throughout thisdocument.

Intra-Device Communications

Power source 100 in FIG. 2 and power box 400 in FIG. 13A can communicatewith more sophistication than the basic resistive-load schema definedabove. With proper power factor correction (PFC) and powerlinefiltering, traditional powerline modulation can be performed over thelow-voltage lines. Since such methodologies are well understood andfamiliar to anyone who is skilled in the art and who is familiar withX-10-style (X-10 USA Inc., Closter, N.J.), or Echelon (Palo Alto,Calif.) powerline communications, they are not detailed here.

Even using two resistors in resistor array 509 that can be switched inand out of powerline 505 and 507 in FIG. 13A, a rudimentary 1 and 0binary “code” can be constructed. Because the voltage along thepowerlines that connect power source 100 in FIG. 2 to power box 400 inFIG. 13A can include two voltages (5 VDC and 28 VDC, for example), theresistor “code” must have two value sets, one for each voltage. Also,since the output-line load downstream of power converter 122A in FIG.13A can fluctuate considerably while powered device 508C is inoperation, adequate power factor correction and line-load filteringbetween power source 100 and power box 400 is important.

See also the section “Software Operation” above, for information aboutpowering an MCU from a battery power source, and the operation of apowerline modulation schema in hardware and software.

Vin differentiators

Vin-detection 803, 804, or 805 differentiates whether software 800 inFIGS. 1A-1-1A-9 is executing with its hardware 400 (FIG. 13A), orequivalent, connected to an automotive or commercial aircraft powersource. Automotive output voltages to devices like those on whichsoftware 800 resides can range from 9-16 VDC. Commercial aviationvoltages are 15 VDC (+/−1 volt), or 28 VDC. While 15 VDC is within thespectrum of automotive output voltages, rarely do automotive voltagesrun that high. Typically 13.5 VDC is the upper limit of real-worldautomotive voltages at the dashboard. Thus, by detecting anddifferentiating input-voltage parameters, software 800 can be configuredto perform functions unique to its operational environment.

As a non-limiting example of which is that aviation functions canpreclude charging the battery of a powered device. FIGS. 6A-E, 7, 8, and9A-D show methods of disabling battery charging, while still deliveringpower to a host device. Software 800 relies on detecting a match forinput voltage as an initial indicator of its operational environment. Ifinput voltage parameters indicate an aviation voltage (15 VDC or 28VDC), software 800 runs subroutines that are specific to unique hardware(connectors referenced FIGS. 6A-E, for example) that are only used oncommercial aircraft. Thus, elemental input-voltage-sensing function insoftware steps 803-805 in FIGS. 1A-1-1A-9 provide differentiators thatdefine intended operations within specific environments.

Output I/O Activity Detection

Before performing any activities related to the power output side of ahardware power box 400 in FIG. 13A, or an equivalent, step 807 insoftware 800 (FIGS. 1A-1-1A-9) locks out any inputs from manual voltageselector 337. All activity of LED 402 is latched up. This isprecautionary, only. Because MCU 102, and not the actual rotating ofmanual voltage selector 337, controls power converter 122A, any usermanipulation of voltage selector dial 504 cannot impact the operation ofpower converter 122A.

Software 800 in FIGS. 1A-1-1A-9 monitors other user activities,particularly those associated with output connector 508 in FIG. 13A. Auser may have to attach a cord 115 and/or a connector (132 in FIG. 2) toconnector 508, for example. In anticipation of this, software 800monitors output powerline activity at MCU inputs 525 and 527, whichcomprises A/D I/O Port #1 (see software step 809, and elsewhere). Ifuser has already attached a connector 132 (FIG. 2) to a battery pack508B (FIG. 13A), battery voltage is available at MCU 102's A/D I/O Port#1. This is feasible, in that a user could have attached a connector132, and connected that to a battery (see FIG. 6B). After having doneso, only then would a user attach the power input lines 505 and 507 inFIG. 13A to a power source. Thus, MCU 102 would be powered only afterthe battery connection was made, so software 800 would be “blind” toprevious battery- and connector-related user actions. Software 800 canbe rewritten to accommodate this. The power from a battery 508B can turnon MCU 102A, using inputs 527 and 525. Thus, MCU 102A can be functionalas soon as power from battery 508B is available on powerlines 523 and524.

Software sequence 809-811 is a simple voltage check at A/D I/O Port #1.If no voltage is present, the user has not yet reached the stage ofattaching power box 400's output cord 523 and 524 to a battery pack (seebattery 355 in FIG. 11, for example).

Having detected, in steps 809-811, no voltage at A/D port #1, software800 in FIGS. 1A-1-1A-9 executes sequence 812-822, which is powerlineload detection. Conductor 519, with its load 521 strapped across toconductor 527, comprises what is identified as A/D I/O Port #3 insoftware flowchart 800 (FIGS. 1A-1-1A-9). This port is a dedicatedcurrent-sensing A/D I/O of MCU 102 A in FIG. 13A.

Look-Up Table

Software 800 in FIGS. 1A-1-1A-9 differentiates from among a series ofeight separate and distinct load-related events. These are defined inline-load look-up table 990 in FIG. 20. States for a power cord,connector, and battery connection are defined. This list assumes that apower cord and connector are discrete assemblies, and that a user mustattach a connector to the cord. Look-up table 990 also assumes thatthere is a cap on a connector (see item 530 in FIG. 6D). Two states LL⁴and LL⁵ differentiate whether a battery pack is removed from, or isinstalled in, its associated powered device. Not all of these statesneed be present for software 800 to operate. These powerline load statesare separately defined to show where, in the sequence of softwareprocesses described in software flowchart 800 (FIGS. 1A-1-1A-9), each ismonitored.

Look-up table 990 (FIG. 20) links an Ohm-value to each configuration ofconnector, cord and battery pack. In software 800, each reference to“Look-up Table of Ω Values” (815, 831, 844, etc.) compares an acquiredpowerline load value to each of the pre-defined resistive values inlook-up table 990. Thus, if the captured Ohm-value in software step 816is 0.32 Ohms, then only LL¹ is valid. The null-value LL⁰ is notconsidered in any of software 800's comparisons, because it indicates nouser activity, and is therefore the absence of any other “LL” value.

All pre-defined Ohm values in look-up table 990 (FIG. 20), are definedin the manufacture of the power cord, connector (and its cover), andbattery packs. Allowable manufacturing tolerance is indicated as 5%.

Voltage Check, Then Load

Software 800 in FIGS. 1A-1-1A-9 is structured so that a voltage checkalways precedes a load check at the output powerlines, for exampleoutput powerlines 523 and 524 in FIGS. 1-1-1-43A. There are two reasonsfor this two-step sequence. Both reasons are related to monitoring useractivities, and knowing what a user is doing with an output power cord508A, its connector 132, and especially a battery pack 508C. First, auser may have already performed an action that is further along inflowchart 800 than the present step in software 800. As a non-limitingexample, if the Vin test in step 809-811 yields a correct reading, step813 indicates a GOTO step 883 “Battery Connected.” If a user connects tobattery 508B prior to software step 809, software 800 has a way ofchecking for such out-of-sequence user activity.

Second, power converter 122A in FIG. 13A must be turned on to do a lineload test during power-output functions. For example, software steps812-822 represent a typical line load test sequence. Power converter122A is turned on in step 812. If, at that moment, a user is inserting aconnector 132 into a battery pack 508C in a manner that will allowbattery voltage to flow (see FIG. 6C), there will be two contendingvoltages on powerlines 523 and 524 of power box 400 (FIG. 13A). If thebattery's output voltage is higher than 3 VDC, power will flow intopower converter 122A's output (this assumes that power switch 526 isclosed). If a battery voltage is less than 3 VDC, power from converter122A will flow into battery 508B. This situation can damage either powerconverter 122A, or battery pack 508C.

Diode protecting power converter 122A's output lines in FIG. 13A isprudent, and has been discussed in the section “Diode UPS” but,incorporating diodes in a battery pack may not be advisable. Diodes inthe battery pack can distort the battery values (particularly voltages)being reported by a smart battery circuit. Optional powerline switch 526can be used as a safety valve. This switch is only closed afterconfirmation that powerlines 523 and 524 are inactive. Software 800handles this issue by always sampling output-line voltage at MCU 102A'sinput lines 525 and 527 (as exemplified in steps 809-811 ) beforeinitiating a load-sampling sequence.

After sampling line load, as exemplified in sequence 812-822 inflowchart 800 (FIGS. 1A-1-1A-9), if no look-up table 990 confirmation ofa resistance-value match is found, software 800 error loops back toanother voltage sampling 809-811. In some software sequences, screendisplays or other user indicators are employed to prompt a user toperform a desired action. A non-limiting example of this is step 834,where a screen display prompts a user to remove the cap from a maleconnector (reference FIG. 6D). Note that the error loop then reverts toa line-voltage check first (steps 823-824 ), before again sampling for achange in load (indicating that the cap 530 has been removed fromconnector 540 in FIG. 6D). Screen displays are discussed in the section“GUI Considerations.”

Making the Batter Connection

Software 800 in FIGS. 1A-1-1A-9 performs a series of output-line voltageand powerline load samplings, starting at step 809 and continuing tostep 876. During these steps, various user screen prompts (821, 834,848, 863 and 876) can be indicated in order to direct a user to properlyconfigure power cord 508A, and the correct Position #1 and Position #2sequencing of connector 132 into battery pack 508B (reference FIGS.6-6C, and FIG. 17).

Once a connector 132 and power cord 508A assembly has been properlyconfigured (FIG. 13A), software 800 continues to perform outputpowerline voltage samplings, as indicated in steps 877-882. This Vinsampling sequence loops continuously, until a line voltage indicatesthat battery 508B is properly connected in its Position #1 to power box400. Once connector 132 is properly mated to battery 508C, a polaritycheck is performed in flowchart 800's step 883A

Acquiring Battery Data

Software 800 in FIGS. 1A-1-1A-9 executes steps 884-892 to acquire abattery Vmax (Maximum Voltage) value. This is a no-load voltage readingof the cells inside the battery housing. MCU 102's A/D I/O Port #1(conductors 525 and 527 in FIG. 13A) acquires this value in step 884.

In step 888, the Vmax value is compared to look-up table 799 (FIG. 15).Look-up table 799 is comprised of a database of individual cellvoltages, with known combinations of cells in battery packs. All commoncell chemistries are charted in look-up table 799.

Look-up table 799 (FIG. 15) is not critical to the proper operation ofsoftware 800. However, there can be battery pack conditions that are atthe fringes of “normal” voltages. For example, a battery pack that is ata very low state of charge. A deeply discharged battery pack conditionwill not distort the Vmax (no load) value acquired in software 800'sstep 884. This deeply-discharged battery scenario is a good reason toavoid using resistors in output power cords, connectors, etc., sincethese will only apply unnecessary loads when acquiring a Vmax value. Ifthe resistance is substantial, the voltage range between Vmax and Vminwill be unnecessarily depressed. Because the battery cells are not underload when the Vmax value is acquired, the battery pack will most likelyread close to its nominal manufacturer's “design” voltage. All batterychemistries exhibit a transient voltage “recovery” characteristic whenat rest. This is often experienced with a flashlight that will no longerlight. After the flashlight rests for a period of time, the bulb willmomentarily respond.

Cell voltage look-up table 799 (FIG. 15), referenced in software steps888 and 899, will aid in identifying deeply discharged battery packs.The Vmin (under load), and Vmax (no load) values will be distorted whencompared to the expected voltage readings for a battery pack that hasbeen charged. Note that batteries that are freshly charged will swing tothe opposite end of the voltage-reading spectrum, with high Vmax (noload) values. In that respect, freshly charged battery packs areconsidered as “abnormal” as deeply discharged ones, when interpretinglook-up table 799.

Vmin

Software 800 in FIGS. 1A-1-1A-9 acquires a Vmin voltage value in steps893-903. A load 517 is introduced in the powerline at MCU 102A'sconductors 522A and 527 as A/D Power Port #4 (FIG. 13A). This loadshould be of sufficient impedance to depress the battery pack 508B'soutput voltage. If the battery packs to be addressed by the inventionare for laptops, as a non-limiting example, the load should be at least750 mA (based on a typical laptop drawing 1.2-1.5 Amps from a batterypack). If the load is too small, there may not be enough differencebetween the Vmax (no load) and Vmin (load) voltage values. Highresistive loads also pull down a battery's voltage more quickly.

A Vmax (no load) voltage value is stored in memory 518A as Vref² (step892), and a Vmin (under load) voltage value is stored as Vref¹ (step 903). If look-up table 799 (FIG. 15) of single battery cell voltages v.cells-per-pack is properly structured, the two acquired voltage valuesVmax and Vmin can determine the optimum output voltage for powerconverter 122 A in FIG. 13A. Step 907 in software 800 determines anaccuracy for values Vref² and Vref¹ with a tolerance of less than 5%,when compared to look-up table 799. This error-factoring rules outlook-up table 799's potential errors, such as in a situation that couldoccur if both Vmin and Vmax were statistically improbable (i.e., valuesdon't fall within a set of known voltage values), or voltages that areotherwise flawed as reliable baseline values.

In steps 913-914 of software 800 (FIGS. 1A-1-1A-9), Vref² and Vref¹ arelisted and sorted in ascending order. If all acquired voltages are froma stable battery pack, i.e., one that isn't freshly charged (orprecipitously near total discharge), the sequence of voltages will be:

-   -   Vref¹    -   Vmin    -   Vmax    -   Vref²

This ordering indicates that look-up table 799's (FIG. 15) valuesconfirmed that there was a correct configuration of cells in a batterypack that, by their design cell voltages, indicated that the actual loadand no-load voltages acquired (Vmin and Vmax respectively) are withinnormal parameters.

If the results of the LIST and SORT processes in steps 913 and 914differs from that shown above, an error state is reported in step 915 ofsoftware 800 (FIGS. 1A-1-1A-9). If the outcome of step 914's LIST andSORT is a valid voltage progression, from lowest to highest, then MCU102A (FIG. 13A) uses Vmin as a first output voltage at which toconfigure the Vout of a power converter 122A.

Vmin and Vmin

The output voltage of a battery pack, under load, is expressed as Vmin.Some battery references may identify Vmin as a battery's ConstantCurrent Voltage (CCV). The input voltage to a battery's powered devicecan also be expressed as Vmin, or the minimum operating voltage of thedevice. Understanding the relationship of a battery's Vmin to itsassociated powered device's Vmin will shed some light on what relevancesoftware 800's voltage acquisition has to successfully delivering anoptimized voltage to a powered device.

For the sake of clarity, battery output voltage Vmin will be labeled,for purposes of this discussion, “BattVmin,” while a powered device'sminimum operating voltage will be labeled “PDVmin.” BattVmin is closelyrelated to PDVmin, because PDVmin determines how deeply a powereddevice's battery pack will be allowed to discharge (expressed here as afunction of voltage, and not a “fuel gauge” reading of batterycapacity). A powered device's minimum operating voltage, ideally, wouldonly be slightly above its battery pack's lowest possible dischargevoltage.

The lowest possible discharge voltage of a battery is determined by a“point of no return” in voltage, below which the battery will facepotential internal cell damage. For example, a Ni-Cad cell, rated at amanufacturer's design voltage of 1.25 volts, would be damaged if thatcell's voltage dropped below 1.0 volts. At such a low voltage, the riskof permanent cell reversal is significant. “Cell reversal” means thatthe cell suffers internal damage which renders the cell incapable ofbeing filly recharged. Thus, for the safety of the battery pack, cellvoltages would never be allowed to drop below 1.0 volts. For a 10-cellpack that is rated at 15-volts, as an example, the lowest BattVmin wouldbe 10.0 volts.

Since manufacturers of powered devices always want to optimize the runtime of the batterypowered product before its battery needs to berecharged, the device's minimum operating voltage PDVmin would likely bevery close to its battery's BattVmin, e.g., 10.0 volts in this example.In reality, the device's lowest operational voltage would probably bebelow 10.0 volts, to allow for the transient sag in the battery's outputvoltage that occurs when the device turns on (sudden load). Althoughdevice manufacturers are often tempted to run the battery voltage downto absolute minimums, a reserve of 10% or more is a often allowed. Inthe case of a laptop computer, for example, this 10% is necessary toallow sufficient battery power for a user to exit all applications andshut down the computer, before the battery reaches its BattVmin voltage.Thus, a 15-volt battery pack, capable of being discharged to 10.0 volts,would have a theoretical artificial PDVmin shut-down voltage (allowing a10% reserve) of 10.1-volts.

Thus, we have the following voltages, in descending order:

-   -   Battery pack design voltage=15.0 volts    -   Device's pre-set battery shut down voltage (BattVmin)=10.1 volts    -   Battery pack minimum safe recovery voltage=10.0 volts    -   Device's minimum operational voltage (PDVmin)=<10.0 volts

It can be surmised that the under-load voltage Vmin acquired in step 896of software 800 (FIGS. 1A-1-1A-9) will be above its powered device'spre-set battery shut down voltage of 10.1 volts. Since the powereddevice's minimum operating voltage (PDVmin) is less than 10.0 volts, anyvoltage above that might properly operate the device. The conditional“might properly operate the device” is relevant, because any inputvoltage to the device below the pre-set shut down voltage of 10.1 voltswould trigger a shut down! But, for purposes of software 800'soptimizing the input voltage to a powered device, as long as the outputvoltage of power converter 122 in FIG. 13A is no less than 10.1 volts,the powered device the converter is powering will operatesatisfactorily. At these extremes of the voltage spectrum, a powereddevice may produce “low battery” warnings.

In reality, the optimum voltage delivered to such a powered device inthe example should be above 11.00 volts. Software 800 operates with aload that is conservative, when acquiring BattVmin (i.e., Vmin). Sincethe 750-900 mA load applied when acquiring Vmin is typically only 50-60%of the operational load of the powered device, BattVmin is slightlyhigher that it would be if a full 1.5 Amp load were applied (assumingthat the battery has already been partially discharged). In light ofthis, the acquired voltage value Vmin should be used only as a firstoutput voltage to a host device. Although not probable, Vmin may notprovide sufficient voltage to properly power the powered device. SinceVmin is below Vmax (see step 907), it is certainly a safe first voltageto apply. The description and figures related to software 101 (FIGS.1-1-1-4) further discuss output-voltage-compensation strategies.

Vmax

Vmax, as a valid voltage value on which to base the output of powerconverter 122 in FIG. 13A can be used as a safe operational voltage forsome battery-powered devices. Vmax is a no-load voltage value. As such,it can be substantially higher than the battery's manufactured designvoltage. For example, a Ni-Cad battery pack having a design voltage of12.00 volts can yield a no-load Vmax value of 14.6 volts, especially ifthe battery has just been charged. Most powered devices allow for areasonably generous over-voltage, because batteries exhibit a transient“pulse” voltage when first turned on that delivers a substantial upwardvoltage spike.

Batteries react to load differently than continuous-power converters.Power converter 122A in FIG. 13A is designed to not exhibit significantvoltage drops under load. Pronounced output voltage drops can createproblems when Vmin- or Vref¹-level voltages are delivered. Under asubstantial load, a voltage drop from a calculated Vref¹ could plummetbelow PDVmin, causing the powered device to shut down.

Having stated that, observations of actual power delivery from anexternal power converter indicate that output voltages at battery designvoltages can trigger unexpected results. In particular, some powereddevices will respond to voltage sags from a battery design voltage bydisplaying user warnings that the battery requires charging. Thisbehavior will also result if the selected voltage is delivered by apower converter that does not also deliver sufficient amperage at theselected voltage. Stable voltage outputs under a variety of loads, andadequate amp-ratings will resolve many of these secondary issues whendelivering power through a powered device's battery port.

Alternative Optimum-Voltage Calculation

Software 800 in FIGS. 1A-1-1A-9 provides an alternative method ofdetermining an optimize output voltage for a converter 122A in FIG. 13A.Steps 909-912 indicate an output-voltage calculation that is bothsimple, and reliable. Acquired Vmin, from steps 893-897, and acquiredVmax, from steps 884-885, are added together, and the result is dividedby two (step 911). The resulting voltage value is stored in memory instep 912 as Vavr (Voltage Average). While this less complicated processfor determining an output voltage may seem too simplistic, it's accuracyis only tainted by battery packs that are deeply discharged. Deeplydischarged batteries exhibit very limited spreads between Vmin and Vmax,and the resulting Vavr voltage can be too low for the powered device tosustain operations, especially if a power converter 122A exhibitsvoltage sags under load. By and large, the calculation method employedin step 911 is very acceptable, and this simple method is also used bysoftware 101 (FIGS. 1-1-1-4).

Determining “Best” Vout Value

Software 800 in FIGS. 1A-1-1A-9 defines steps 940-946 as determining the“best” power converter output voltage (Vout) value. Twovoltage-optimization methods are indicated, as in the discussions ofsteps 911 and 918 in the section below “Is It ON?”. Since the powereddevice has not yet To this point in software 800) been tested witheither the method of step 911 , or step 918's method, it would seem thatselecting the “best” voltage method is impossible. Essentially, that istrue. However, both voltage-optimization methods discussed here have acommonality, and even some similarities. The commonality is that,barring any rejections because of acquisition or calculation errorsduring each process, both methods will yield output voltage values thatare between a powered device's PDVmin (shut down) and a battery'sno-load Vmax (peak voltage).

The similarity of the two voltage-determination methods is that theresulting voltage from one method is usually quite close to the resultof the other. Vmin and Vavr tend to be voltage values within 10% of eachother. This is true only if a battery is neither freshly charged, nordeeply discharged. The more complex method involving look-up tables (seesoftware steps 884-908 in software flowchart 800 in FIGS. 1A-1-1A-9)will quickly detect these extreme cases, while the simple calculationmethod expressed in step 911 won't.

To more efficiently determine which of the two methods is the mostprobably reflective of the true charge/discharge state of a batterypack, software solutions such as fizzy logic, expert-rules-based logic,or adaptive neural networks will reveal probabilities of success.However, such complex approaches, while acknowledged as potentiallybeneficial, would tax the processing and memory power of an MCU 102A(FIG. 13A). Such complex software is also not justifiable, because thenumber of probable failures to power a device using the two definedmethods in software 800 are statistically near zero. The various look-uptables use din software 800 (FIGS. 1A-1-1A-9) and 101 (FIGS. 1-1-1-4)provide a basis for exploring artificial intelligence. Also, many of the“rules” expressed tacitly and implicitly through the decision tress,calculations, and error loops of software 800 and 101 point to arules-based expert system. Those skilled in the art of artificialintelligence software will be able to integrate fuzzy logic, adaptiveneural networks, and similar disciplines into software 800 (or 101).

It must be kept in mind that battery-powered devices exhibit a widerange of tolerated input voltages between Vmin and Vmax. Only fringesituations, more related to those battery packs that are deeplydischarged than those that are freshly charged, may precipitate powerdelivery errors. If properly constructed and used, the look-up tablesassociated with steps 888 and 899 in software 800 will almost totallyeliminate problems associated with deeply discharged batteries. Thesemostly-depleted batteries will be quickly identified by Vmin and Vmaxvoltages that fall outside values in look-up table 799 (FIG. 15).

Use of Impedance

Battery cell impedance can be a valid indicator of cell type. All cellsincrease impedance as a function of discharge. As such, decreases involtage have some relationship with changes in battery discharge levels.So too, do impedance changes reflect battery discharge states. Thesechanges in voltage and impedance aren't very pronounced in Ni-Cad andNiMH cell chemistries, but Li-Ion cells do show clearly definedimpedance changes that track with decreases in voltage. Impedance checkscan be integrated into software 101 or 800 (FIGS. 1-1-1-4 and FIGS.1A-1-1A-9, respectively), if further granularity in identifying abattery pack's discharge state is required. Such added complexity isusually unwarranted, since it will only come into play when the Vmin andVmax readings are from a deeply discharged battery pack. Even then,battery's and powered device's power circuits are designed to allow asufficient battery reserve that Vmin and Vmax will still be reliableindicators. Do not use impedance testing if diode 185 in FIG. 6E isimplemented, or if the smart circuit is wired into the powerlines, asshown in FIGS. 9A and B.

Manually Selecting Output Voltages

Step 942 in software flowchart 800 (FIGS. 1A-1-1A-9) activates manualvoltage selector 337's I/O line 506 in FIG. 13A. A user, by rotatingselector dial 504, can match MCU 102A's “Best” output voltage value(step 946).

In the alternative, MCU 102A can compare a user's voltage selection tosoftware 800's “best” voltage selection, and confirm if they are amatch. The perspective as to how the computed best voltage value and auser's selected output voltage value interact is left to the discretionof a product designer. This model of considering a user-selected voltageas the constant to which a best output voltage is compared applies tohardware applications like those in FIGS. 10 and 11. If a power adapter335 is of a fixed output voltage, a software-800-enabled module 357gives a user feedback as to whether the fixed-voltage power adapter 335is an adequate match to voltage requirements of a powered device 349.

MCU 102 A retrieves from memory stored voltage values in steps 940 and944. How the “best” voltage is determined is discussed above in“Determining ‘Best’ Vout Value.” Once the best Vout value is determined,that value is compared to a pre-configured look-up table of possibleselector voltage values (step 950). This look-up table (not shown)consists of each voltage value on the face of selector 337, with anassigned computer-readable value (binary, hex, “byte-word,” etc.).Software 800 converts the “best” Vout value to the same language(binary, hex, byte-word, etc.), then looks for an exact match in thislook-up table.

Software 800 in FIGS. 1A-1-1A-9, having compared (in step 952) it's“best” output voltage value to the voltage values available on selector337's dial face (FIG. 13A), determines whether or not an availableselector-dial value will exactly match the computer-generated “best”Vout in step 954. If the answer is NO, step 960 looks for a reasonablematch, i.e., one that is within +/−5% of the desired value. If thisstatement fails, a critical error is generated (step 962), which loopssoftware back to steps 885-918 (this loop is not graphically shown inflowchart 800). In looping back to the voltage calculation processes, nonew data acquisition is performed. Instead, previously-acquired voltagevalues are retrieved from memory and recalculated. Steps that involveuser activities are also eliminated in this voltage-value recalculationloop. If the voltage recalculation (steps 885-918) fail a second time,software 800 would shut down power converter 122A (FIG. 13A). The userthen would be prompted to restart the entire process.

If a selector dial 337 voltage value is not an exact match tocomputer-generated best Vout (steps 952, 954 ), but is within softwarestep 960's +/−5% allowable error factor, software 800 is conservativeand accepts a “near-best” selector-dial voltage as the target (step 968labels this voltage value as VLout). Voltage target VLout is stored inmemory in step 964, for later access. If there was an exact matchavailable as a result of comparator step 954, it is labeled as Vbst instep 958, and stored for future reference (step 956).

Following the operation of software 101 (FIGS. 1-1-1-4), a softwaresequence can be implemented into software 800 whereby MCU 102A's “best”output voltage value (step 946) overrides any considerations of a user'sincorrect manual voltage selections. Thus, if the user fails tomanipulate voltage selector 504 (FIG. 13A), or continues to selectincorrect voltages, software 800 defaults to applying MCU 102A's “best”voltage value instead. The techniques for such software are to be foundin the sections which discuss software 101, and which are illustrated inFIGS. 1-1-1-4.

LED-Assisted Voltage Selector Operation

Previously described selector voltage value look-up table in the“Manually Selecting Output Voltages” section above contains the voltagevalues displayed on the face of selector 337 (FIG. 13A) arranged inascending order. The programming code considers the“voltage-to-be-matched” as a target, and each incremental voltage valueabove or below it is considered x-points away from the target voltage.Thus, as a non-limiting example, if the design of the hardware is tohave a user rotate selector dial 504 until its pointer matches MCU 102's“best” voltage value, software 800 assists the user by indicatingwhether the user is turning selector dial 504's pointer closer-to, orfarther-from the target voltage. For example, if the target voltage is12-volts, and the pointer on selector dial 504 is at 18-volts when auser starts the voltage-match process, should the user move the dialpointer from its present position at 18 to a new position at 19,software 800 would detect the look-up table's point count moving in thewrong direction, i.e., moving away from the target voltage, instead oftoward toward it.

In the non-limiting example used throughout this section, voltage-matchconfirmation is indicated to a user via LED 402 in FIG. 13A. LED 402features variable-rate blinking. As user moves selector dial 504 furtheraway from the target voltage, software 800 uses point-count valuesassociated with all voltages above and below the target voltage tocontrol the blink rate of LED 402. Slower LED blink rates are associatedwith voltage values farthest from the target voltage. Faster rates occurat numbers nearer to the target voltage value. The fastest LED blinkrate occurs at the voltage values directly adjacent (on either side) tothe target. Thus, the LED blink rate assists a user's manipulation ofselector dial 504 by blinking more slowly as pointer 504 is rotated awayfrom the target voltage. More rapid blinking occurs as selector dial 504is rotated in a direction toward the target voltage. Final visualconfirmation of a valid voltage match is a non-blinking, solid ON stateof LED 402.

When software 800 in FIGS. 1A-1-1A-9 is ready to accept a user-selectedvoltage in step 966, there is either an exact-matching (oralmost-exact-matching) voltage value that serves as a target. Step 970indicates that either Vbst (an exact voltage match), or VLout (analmost-exact voltage match) is available as a target. Since the criteriafor a valid VLout “almost-exact” voltage is that it must be within 5% ofan exact match (see step 960), the use of VLout is not necessarily aless-effective target voltage. As a hypothetical example, if the Vbstvoltage (exact match) happened to be 16 volts, a corresponding VLout(almost-exact) voltage target can be as high as 16.9 volts. The nearestselector 337 value is 17 volts, so 17 volts would be the valid target.Note that, even though 15.1 volts would mathematically be as“almost-exact” a valid target as 16.9 volts, such split-decisions thatprecisely straddle a Vbst value always defer to the higher voltagevalue. The higher voltage is preferred because a 5% error factor ismagnified at the higher voltages. A 5% error at 3 volts is only 0.15volt, while 5% of 24 volts is a full 1.2 volts. Another way of lookingat the 5% error-factor is that it would depress all battery designvoltages by a full 5% if the lower voltage value approach was used.Essentially, a battery pack rated at 15 VDC by the manufacturer would betreated as a derated 14.25 VDC pack, just because of the allowablevoltage selector error.

Software 800 in FIGS. 1A-1-1A-9 can also employ an alternative Booleanstatement to determine the relative blink rate of an LED 402 (FIG. 13A).Instead of a point count that controls the blink rate of the LED,software steps 970-994 describe an LED blink-rate control that comparestwo acquired voltages. One of the two acquired voltages will always becloser to the target voltage than the other. Instead of using absolutecomparisons of each acquired voltage to the target voltage value asdescribed above, software 800's Boolean statement determines therelative relationship of the last two previous voltages acquired. Forexample, assuming that the target voltage is 15 volts, if the firstacquired voltage from selector 337 (step 970, then stored as a value VS1in step 974) is 9 volts, and the second acquired voltage from selector337 (step 976, then stored as VS2 in step 978) is 7.2 volts, a simplemathematical comparison of VS1 to VS2 is performed:Vbst (actual target voltage)−VS 1=“X”Vbst (actual target voltage)−VS 2=“Y”or 15−9=6 (X)15−7.2=7.8 (Y)

Then, “X” and “Y” are compared, to determine if the first acquiredvoltage is larger or smaller than the second acquired voltage:Is “Y”>“X”?orIs 7.8>6?

If the answer is TRUE (YES), then the voltage selector is being rotatedaway from the target voltage. If TRUE is reported, the LED blinks slowerthan the last reported answer.

If the answer is FALSE (NO), then the voltage selector is being rotatedtoward the target voltage. if FALSE is reported, the LED blinks fasterthan the last reported answer.

NOTE: any voltage values higher than the target voltage will yieldnegative numbers when deducted from the target, i.e.:Vbst (actual target voltage)−VS 1=“X”Vbst (actual target voltage)−VS 2=“Y”or15−18=(−3)15−19=(−4)

Negative numbers are considered as their positive counterparts. Thus, avalue of “−3” is treated as “3,” and “4” is read as “4.” This eliminatesthe need to know whether the selector dial is at values above or belowthe target value, since the Boolean statementIs “Y”>“X”?would have to be inverted for values above the target voltage.Discarding the “−” sign avoids this complexity in a straightforwardmanner.

Since the blink rate is relative only to a last-reported result, and notrelative to the target voltage value, the first blink rate is determinedarbitrarily. Thus, if selector dial arrow pointer is only twodial-indicators away from the target, the first blink rate is“medium-slow,” and the next blink rate (the selector arrow is now onlyone value away from a match) is a “medium” blink rate. If the selectormatches the target on the next dial movement, the LED goes to full-ON.The user is only concerned with achieving a selector rotation directionthat is an improvement, so the relative speed of the LED blink isimportant.

Connector Unplugged

Software 800 in FIGS. 1A-1-1A-9 uses a line-voltage test (steps 922-926), followed by a line-load test (steps 928-938 ), to determine that aconnector 132 (FIGS. 13A, and 6) has been removed from battery 508C.Once output voltages have been calculated, the user activity of removinga male connector 132 from battery pack 508B (FIG. 13A) is important. Inits Position #1, connector 132 creates a circuit that could cause powerfrom a power converter 122A to flow into the cells in battery 508B. Thisis not desirable. Software 800 relies on its model of always repeatedlysampling powerline voltage to determine if battery 508B is in the powercircuit. Once the battery voltage on the powerlines is no longerdetected, in steps 922 and 924, software 800 has successfully confirmedthat connector 132 has been removed from battery pack 508B. Also, asdescribed in software 101 (FIGS. 1-1-1-4), power converter 122 A alwaysoperates at a minimal output voltage (1.5-3 VDC) through all softwaresequences before step 983, when a full operational voltage is applied tothe powerlines.

The next connector 132 insertion will look like that shown in FIG. 6C(reference Position #2 in FIG. 17). Battery 182 has beenelectromechanically bypassed, and the newly created circuit will deliverpower directly to battery 508B's associated power device 508C. Becausepower will be flowing from power converter 122A in FIG. 13A connector132, a reinsertion of connector 132 oriented again as it was previouslyin FIG. 6B (position #1) will cause power to flow into battery cells182. This is undesirable.

Given this situation, hardware design can add a layer of safety, interms of supporting software 800 to ensure that a connector 132 isremoved and no longer in Position #1. FIGS. 13 and 13-1 shows voltageselector 337 being manipulated with a male connector 404 (connector plug404 is best illustrated as connector 540 in FIG. 6D). Blade tip 548 inFIG. 6D fits a slotted selector dial 504 in FIGS. 13 and 13-1. A userneeds a male connector 404 in order to operate voltage selector dial504. Therefore, software 800 can rely on the fact that, if activity atvoltage selector dial 504 is detected (as it would be along conductor506 in FIG. 13A), a male connector 404 (FIGS. 13 and 13-1) is notconnected to a battery pack at that moment.

This user activity of using the tip of the male connector as a tool torotate the manual voltage selector can be verified by repeating software800's steps 922-938 (FIGS. 1A-1-1A-9). Software steps 922 and 926 willverify that no voltage from a battery is flowing on the output powerlines. Software 10 steps 928-938 (line load test) will further indicatethat male connector 404 in FIG. 13 is either attached to a power cord(assuming that the male connector is removable), or that it has beenremoved. In look-up table 990 (FIG. 20) Ohm-value LL¹ indicates that aconnector 404 has been removed from the cord, while Ohm-value LL³ showsthat a cord and connector 404 are mated.

If the shaft below selector dial face 504 in FIGS. 13 and 13-1 isslotted 337A to a depth that allows the entire blade of male connector404 (reference detail in FIG. 6D) to be inserted, a resistor 337B can beintegrated into the slot. The metal tip 548 of male connector 404 comesinto electrical contact with resistor 337B, creating a circuit. Software800 then detects the actual presence of the male connector's blade inthe dial slot, via a line between resistor 337B and MCU 102A's A/Dconverter. This would require an entry in look-up table 990 (FIG. 20)expressed as LL⁸. This Identifier would express an Ohm-value thatequates to the cumulative load of a power cord, connector 404, and thenewly added resistor 337B. This approach is similar to the use of aresistor-equipped cover cap 530 for connector 540 in FIG. 6D, which isreferenced as if it were here in its entirety. Newly-created resistorvalue LL⁸ should not be the same Ohm value as that used in cap 540, toavoid confusing LL⁸ with LL². This methodology is only valid ifconnector 540 cannot be removed from its cord.

By using a male connector 404 in FIGS. 13 and 13-1to rotate selectordial 504, software 800 can account for the whereabouts of the maleconnector, especially that male connector 404 is not inserted in abattery pack. User selection of an output voltage by rotating selectordial 504 creates a time period during which software 800 does not haveto address a user's possible incorrect reinsertion of male connector 404into a battery pack. By continued sampling of line voltages and lineload (steps 922-938), software 800 tracks user activities with a maleconnector 404 with better accuracy, but it is described in the text andfigures for software 101 in the Description, and is referenced here asif were here in its entirety.

Avoiding “Blind” Power Application

The section “Connector Unplugged” above defines a method of tracking amale connector 404 (FIGS. 13 and 13-1), once it is removed from abattery pack (see software 800's steps 920-938 in FIGS. 1A-1-1A-9).However, there is still a period of time during which a user is expectedto reinsert male connector 404 into a battery pack. Male connector 404must be inserted in its Position #2 (reference FIG. 6C), and not in itsprevious Position #1 (see FIG. 6B). If a user reinserts connector 404 inPosition #1, an application of power from power converter 122 in FIG.13A onto powerlines 523 and 524 will find the battery voltage alsopresent on that line. Such contention on the powerline is to be avoided,since it can compromise either battery cells 182 (FIG. 6B), or powerconverter 122A

Software 800 is limited to detecting line voltages, since sampling lineload requires outputting a low-voltage power signal from power converter122 onto powerlines 523 and 524 (FIG. 13A). Sampling line voltage onlywill not yield sufficient data at MCU 102 A to allow software 800 todifferentiate between a removed male connector 132, and a male connector132 that is properly inserted in its Position #2 (see FIG. 6C). If thebattery voltage is higher than this low-voltage power signal, thedominant battery voltage will flow into the active power converter 122.

This dilemma can be resolved in several ways with slight changes inhardware. A straightforward approach is to diode-protect power converter122. Strapping a diode between the positive output powerline at TB1 (inFIGS. 4-1 and 4-2) and pin 20 (ground) on connector header J1 will avoidbattery power driving into a power converter 122 (FIG. 13A).

Female connector and wiring in assembly 212A (FIG. 6E) can be protectedwith diode 185 on spring-loaded connectors 176 and 178.

A user who has invested the effort to construct a connector and cordcombination, removed a connector cap (FIG. 6D), inserted that connectorin its Position #1 (reference FIG. 6B), then removed the connector andused it to adjust manual voltage selector 504 (FIGS. 13 and 13-1),exhibits behavior that has a high probability of continuing the processby completing the remaining last action inserting the connector into thebattery pack. Common sense suggests that, since a user is performingthese actions in order to use a powered device, that the sequence ofactions will be completed.

Given all of the above, software 800 can safely proceed to step 985 andturn on power converter's output voltage with little concern forencountering a connector that is not connected to its associated batterypack. A male connector 132 can only be in three states:

-   -   1). Male connector 132 is not attached to anything (FIG. 6), or    -   2). Male connector 132 is attached to a battery pack in        incorrect Position #1 (FIG. 6B), or    -   3). Male connector 132 is attached to a battery pack in correct        Position #3 (FIG. 6C).

If power is delivered from power converter 122A in FIG. 13A to a maleconnector 132 in states #1 or #3 above, no consequences are incurred.Since software 800 continues to perform line voltage and line load tests(steps 961-945 ) as soon as low-voltage output power is turned on,confirmation of states #1 or #3 will be immediate.

If male connector 132's possible state #2 occurs, the continuous linevoltage samplings (steps 987-985 ) performed by software 800 immediatelydetects the voltage from a battery. Thus, the window of time in which auser error inserting a male connector incorrectly can happen only in themilliseconds it takes to loop back to a repeat of a line voltagesampling sequence 987-985. In conclusion, any real-world concern aboutdelivering power to an incorrectly inserted male connector isstatistically insignificant. If there is a concern, adequate hardwaremodifications within a battery pack, as described above, can be made tototally eliminate any possible ambiguous situations.

“No Activity” State

Since MCU 102A (FIG. 13A), is capable of determining an optimized outputvoltage for power converter 122A, user activity at selector dial 504 isnot essential to the operation of software 800 and its related hardware.Therefore, a lack of response from a user in software steps 942-998should not prevent software 800 (FIGS. 1A-1-1A-9) and its hardware fromexecuting the remaining sequences required to deliver output power. Areasonable amount of time should be allocated during which software 800will expect user voltage-selector 504 activity. Since MCU 102A doesprovide a clock generator (152 in FIG. 3A), a timing function can beused to establish a window of anticipated selector dial 504 activity.This function is not detailed in software flowchart 800, but one skilledin the art can implement this additional timing sequence.

Software 800 does have certain indicators that point toward a userhaving omitted the voltage selector sequence 942-998. The primaryindicator is the location and position of a male connector 132 in FIG.13A (reference FIGS. 6-6C). As previously noted, connector 132 can onlybe in one of three states: still inserted (see FIG. 6B), removed (seeFIG. 6), or reinserted in its next position (see FIG. 6C). The processesof determining these connector states has already been addressed, bysampling line voltage and line load (see chart 1001 in FIG. 17, and therelated description for software 101).

Once the removal of connector is detected in software 800 (steps922-938), the next activity is that of a user rotating voltage selectordial 337 (FIG. 13A), in preparation for reinserting connector 132 intobattery 508B. A time delay allocated for this anticipated next useractivity is important. Assuming that there is no method available forprompting a user to reinsert connector 132 (step 936), software 800 hasno choice but to wait. The section “Disconnected Selector ‘Key’” aboveaddresses various monitoring steps performed by software 800, todetermine when connector 132 is removed and reinserted.

NOTE: Power box 400 (FIG. 13A), does have one user prompting device. LED402 can be an effective attention-getter. Blinking the LED at differentrates (or having it change colors) helps to focus a user on the nextrequired connector action.

NOTE: The sequential reference numbering in software flowchart 800 stopsadvancing at step 998, then continues with declining numbers at step995.

Final Vin and Line Load Samplings

Steps 987 and 985 in software flowchart 800 (FIGS. 1A-1-1A-9) representthe last voltage check prior to activating power converter 122A (FIG.13A). This Vin sampling loop, like all others in software 800,continuously repeats, and is always followed immediately by a line-loadtest (steps 983-973). Vin test 987-985 is looking for a no-line-voltagestatus, prior to executing line-load test 983-973. If Vin test 987-985reports back a state of voltage on the powerlines, male connector 132has been incorrectly inserted into battery pack 508B (as indicated inFIG. 6B). The resulting error state causes software 800 to loop back tostep 989.

A final load test in steps 983-973 prior to activating power converter122A (FIG. 13A) is identifying a resistive load value on the powerlinesthat validates male connector 132's proper insertion into battery pack508B (reference FIG. 6C). The load-value for this state is not fullyknown. It cannot be, because software 800 and its associated hardwarehave no determination capabilities of whether it has interacted withthis specific powered device 508C. Each device—including its associatedbattery—to which the system described herein will be connected isconsidered by the software to be a previously unknown battery-powereddevice. Every powered device will exhibit different load values,resulting from the impedance of circuits inside the powered device 508C(downstream of battery pack 508B).

However, software 800's look-up table 990 (FIG. 20) can know itspre-determined load value LL⁴. The load values of all hardware elements(power cord, male connector, and battery pack wiring) are known, becausethey are manufactured to exhibit specific identifiable resistive loads.LL⁴ is an Ohm-value expression of the mathematical sum of the threeelements: power cord, connector, and battery pack. If internal batterypack wiring circuits in FIGS. 9A-9D are manufactured to return a fixedimpedance value, then LL⁴ in FIG. 20 is predetermined. Since LL⁴ has aknown resistance (Ohm) value, any load detected in software 800 steps983-973 that is greater than (>) LL⁴ is considered to be the additionalload added by a powered device's internal circuitry. This circuitry in apowered device exists between the device's battery contacts and theON/OFF switch, and it typically will include a charging circuit, andpossibly elements like a battery selector and keyboard controller. Thus,LL⁵ in look-up table 990 is defined as any load that is greater thanLL⁴, but only if the resistive value of the battery pack's internalwiring is known.

As will be seen, capturing and logging the value that becomes LL⁵ isnecessary, because it is needed later in software steps 951-945, andsequence 927-923.

“OFF” Selector Mode

Steps 996-997 in software 800 (FIGS. 1A-1-1A-9) define the resolution ofuser manipulation of voltage selector dial 337 (FIG. 13A), with step 996being the command from MCU 102A to turn LED 402 full ON (no blink),indicating to the user a successful voltage match. Software 800 thenshuts down Selector I/O line 506 in step 997. Once selector I/O 506 isshut down, no activity at selector dial 504 is acknowledged by MCU 102A,or its associated software 800. The safety aspects of this are obvious.This is a useful feature if a power adapter 400 is used on an airplane,or other confined area where power problems can pose serious safetyrisks.

There is, however, one exception to this total disengagement of selectordial 337 (FIG. 13A). The “OFF” selector dial position has a separateline 511 to MCU 102A. The OFF selector setting is effectively a user“panic button.” A user can totally shut down power box 400 by turningselector pointer 504 to the OFF position. The detents on either side ofthe OFF position are more aggressive than the others on dial 337, so auser must make a concerted effort to put pointer 504 into the OFFposition. The area of the faceplate at the OFF label is painted red toindicate the special significance of “OFF.”

The user does have to disconnect a male connector 132 (reference FIG.6D) or equivalent, in order to rotate selector pointer 504 (see 404 inFIGS. 13 and 13-1) . . . and, disconnecting power is exactly the desireduser response to an emergency situation. Disconnecting male connector404 in FIGS. 13 and 13-1 will not compromise the operation of a powereddevice, since female receptacle assembly 179 (FIG. 6) closes its springcontacts 176 and 178, allowing battery 182 to take over the task ofpowering its associated device (see also an alternative safeguard inFIG. 6E, and related text in the section “Diode UPS”).

Reconfiguring Input Power

As indicated in the section “Software Operation,” power box 400 (FIG.13A) and its associated software 800 (FIGS. 1A-1-1A-9) are capable ofcommunicating with its input power source (reference module 100 in FIG.2). Software 800 manipulates resistor array 509 in power box 400, addingresistive elements to create a discernible change in the overall loaddetectable at input powerlines 505 and 507 (powerlines 505 and 507 inFIG. 13A are the same as powerlines 114 and 116 in FIG. 2). Such is thecase in software step 997. When a voltage match at selector 337 has beenachieved, LED 402 is illuminated full ON (step 996). In conjunction withthis, a discernible power load is created, by inserting a load fromresistor array 509 on powerlines 505 and 507, as a non-limiting example.

This pre-determined increase in load from resistor array 509 in FIG. 13Ais sensed by power module 100 in FIG. 2, which is already delivering avoltage (3-5 VDC, for example) to power box 400 in FIG. 13A. Thisincrease in line load indicates to software 101 (FIGS. 1-1-1-4) residenton MCU 102 (FIG. 2) that power box 400 has issued a call for increasedpower. Power module 100 responds by increasing power supply 122's outputvoltage to a pre-determined value, for example, 28 VDC.

Software 800 in power adapter 400 samples input line voltage at MCU102's A/D I/O Port #2 (518), and detects the change in input voltagefrom a low voltage (3-5 VDC, for example), to the new higher voltage(see software steps 995 and 993). Sufficient input power for DC/DCconverter 122A is now available.

Resets and Resumes

Although it is acceptable for MCU to go off-line momentarily during thechange in its input voltages described above in “Reconfiguring InputPower,” this would not be the best method for such a transition. Amongthe many reasons why a full shutdown of all systems in power adapter 400is inadvisable is that the timing of such an event would be difficult todetermine without a reliable communications link between power box 400(FIG. 13A) and power module 100 (FIG. 2). As a non-limiting example,power box 400 could shut down, not realizing that power module 100 hadnot received power box 400's signal to increase voltage. Although therisk-tolerant design of power box 400 and its software 800 allow for aclean recovery from a shut down, this would pose some awkwardness, notthe least of which is that a user who had just finished receiving avoltage match confirmation (as a solidly lit LED 402), would see the LEDgo out for a brief period of time.

Software 800, in its shutdown mode (not detailed in software flowchart800 (FIGS. 1A-1-1A-9)), loops back to step 807, but not before writingall stored values to non-volatile memory. Such a reset allows software101 to recover, and to even go back to the last executed step prior toshutdown, if necessary. As a default, this mode of resuming from thelast-executed line of code is not prudent. First, depending on where inthe sequence of interrelated event sequences software 800 shuts down, auser may perform some undetected and undesirable activity, such asremoving a connector 132 in FIG. 13A, and reinserting it in an unwantedposition. This could happen, since the extinguished LED couldprecipitate such user behavior.

Another reason to consider not employing a full resume after shut downis that power adapter 400 does not have a battery backed-up clock. Afirst user, seeing the LED extinguish during a planned input voltagechange, could disconnect power box 400 (FIG. 13A) from its power module100 (FIG. 2) at connector 103. This first user may leave and, someindeterminate time later, a second user may connect a different poweradapter 400 to the same power module 100. Neither device can distinguishthis series of events as being anything different than a momentaryshutdown of power adapter 400, while power module 100 reconfigures itsoutput voltage. It is much safer, and efficient, to treat every shutdownas the termination of all activity. Resetting at software step 807 isthe only reliable way to deal with all such critical error events. Theonly reasonable reset-and-resume event in software 800 is the voltagetransition at step 965.

Keeping the MCU Up

Instead of shutting down MCU 102A (FIG. 13A) momentarily while powermodule 100 in FIG. 2 switches from a low voltage output to a highervoltage that is required to drive power converter 122A, MCU 102A can bekept active by traditional temporary power storage methods. Thesehold-up methods can include an internal battery. (see also FIGS. 6E to6F-1, and related text in the section “Diode UPS”).

User Prompts

Step 991, and 989 (FIGS. 1A-1-1A-9) indicate prompts to a user. Thefirst prompt is to reattach a male connector 540 (reference FIG. 6D) toits power cord. If the cord and male connector are hardwired, thisprompt is not required. Step 989 prompts a user to insert a maleconnector 540 to a battery pack in its Position #2 (see FIG. 6C). Ifthere is no adequate prompting method, such as a display screen, seriesof LEDs (see FIGS. 1-1-1-44), etc., then steps 965 and 967 are notexecuted.

Whether software 800 has user prompts available is not very material.Users only have to perform elemental, easily-executed connector-relatedevents. LED 402 available on power box 400 (FIG. 13A) can be aneffective way of signaling a user to move the process along. This methodmust be used with caution, so as not to confuse a user who only expectsto see LED activity while engaged in rotating voltage selector dial 337.A multi-color LED can be beneficial here, perhaps with a label suggestedby the non-limiting example in FIGS. 1-1-1-44.

Power Delivery

After the correct output voltage “Vout” is configured (software step969) at power converter: 122A in FIG. 13A, software 800 activates theoutput of power converter 122A in step 965. If optional power switch 526is employed, it is held open at this point. The output of converter 122Ais thus available on the main powerlines 523 and 524. It is desirablenot to have power flow into battery 508B's circuitry until after thecorrect Vout of power converter 122A is verified by to MCU 102 A. A/DI/O lines 525 and 527 can be used to confirm that converter 122 A isdelivering the correct voltage. However, since MCU's A/D lines 525 and527 are downstream of power switches 526 and 526A, the way to preventpower delivery to a battery circuit 508B is to include a controllablepower switch 508G in the battery's circuit. Battery MCU 102D controlspower switch 508G. MCU 102A in power box 400 communicates a request toopen switch 508G by powerline modulation to battery 508B's MCU 102D (asdescribed in the sections “Data Paths,” and “Other Data Links”).

Software step 953 compares MCU 102A's commanded voltage to converter122A with the actual output of converter 122A. If there is a mismatch,error 959 is reported, and software 800 loops back to step 969 toconfigure the converter once more. If both the commanded voltage and theactual output voltage match in step 953, software 800 signals MCU 102Ato open switch 526. Power then flows along powerlines 523 and 524 toconnector 508, then along power cord 508A, into connector 132, thenthrough battery pack 508B's wiring, and finally into powered device508C.

Two line-load checks are performed in software steps 951-933. These twoline-load samplings constitute a final check that the power circuitryfrom power box 400 to powered device 508C is still intact.Previously-stored line load value LL^(G) (see step 971) is retrievedfrom memory 518A Look-up table 990's value LL⁵ (FIG. 20) is used as abaseline, since Ohm value LL⁵ is a valid load value that tested theentire circuit.

Software step 951 acquires this line load value. In step 949, acalculation is made to provide an Ohm value at the new output voltagethat is equivalent to the LL⁵ Ohm value previously acquired in step 981at a lower voltage. This value is stored in memory as LL⁶. Finally, instep 957, the newly-acquired Ohm value LL⁶ is compared to LL⁵. If thevalues (with this mathematical adjustment for different voltages) arethe same, a user prompt is displayed that the powered device can beturned on (step 929).

Voltage Compensation

The line-load sampling sequence in steps 917-913 utilizes resistive load517 at MCU 102A's A/D I/O port #4 (conductors 522A and 527 in FIG. 13A).This load test provides an opportunity to observe how power converter122A responds to a reasonable simulation of a total system load. Theload at A/D I/O Port #4 should be in the range of 600-900 mA. 750 mA isa reasonable value. Step 937 samples line voltage, while the additionalload in steps 917-913 is still applied. If the output voltage of powerconverter 122A drops by 5% or more (step 913), step 911 increasesconverter 122A's output voltage by 10%.

This voltage compensation step is not necessary if power converter122A's design adequately protects against voltage sags. In reality,power converter 122A cannot be a perfect power conversion device acrossits 3-24 volt output range. So, performing a voltage compensationsequence is a reasonable way to enhance a power converter 122A'sinherent voltage stability limitations.

Is It On?

The issue of user prompts, or lack thereof, has already been addressed.Power box 400 in FIG. 13A continues to monitor (step 909) powerlineactivities throughout its operational use. Repeated samplings of lineload can provide information as to whether a powered device 508C hasbeen turned ON (and later, turned OFF). Steps 927-923 are a repeat ofsoftware 800's previous line-load sequence in steps 951-945, except thenewly acquired Ohm value LL¹ is compared to the stored LL⁶ value. If LL⁷expresses more load than LL⁶, then it is reasonable to assume that theincrease can be attributed to the powered device 508C being turned ON.The value of LL⁷ is stored in memory 518A.

Software 800 continues to sample line load by repeating steps 927-923.As long as a reported value of an LL¹ that is greater than LL⁶ isreported, software 800 assumes that powered device 508C (FIG. 13A) isstill turned ON. If an LL⁶ value is acquired, it can be safely assumedthat powered device 508C has been turned OFF, and that power cord 508Aand connector 132 are still attached to battery pack 508B. One cannotcompare any acquired LL⁷ value to any other. Powered devices exhibitdynamic, not static, loads, so the only valid logic statement that canbe used is that if an LL⁷ is greater than the stable value of LL⁶, thedevice must be ON.

Line-voltage samplings are also continued. If line voltages fluctuate,either upward or downward, software 800 can correct any irregularitiesby issuing commands to power converter 122A to increase or decrease theVout setting. These sequences are not specifically defined in softwareflowchart 800 (FIGS. 1A-1-1A-9), but the numerous references to linevoltage sampling and voltage commands allow one skilled in the art toadd these software functions. This process shouldn't be over-done. Allpower converters exhibit some voltage fluctuations, so the use ofsoftware compensation is to be done sparingly and judiciously. Animportant element that will moderate excessive voltage compensations isthe duty cycle at which voltage samples are acquired. The more frequentthe sampling rates, the more probable will be unnecessarysoftware-driven voltage compensations. Also, any individual voltagecompensation should be evaluated relative to the baseline voltage Voutin step 969.

Helpful information to avoid excessive voltage compensations 911 inFIGS. 1A-1-1A-9 can include tracking voltage adjustment trends. Aconsistent pattern of upward adjustments is a reasonable indicator thatthe baseline voltage stored in step 957 was too low. Determining anincrease in baseline voltage is not a simple matter, so it should alwaysbe approached cautiously and with a substantial, long-term voltagehistory to support the decision. As a non-limiting example, if power isbeing delivered to a laptop computer, initial deviations in load (whichprecipitate voltage fluctuations) are usually created by the BIOS POSTactivities, as powered sub-systems and devices are intentionally turnedON and OFF. These hardware activities are not representational ofanything but BIOS diagnostics. Hardware devices cycled ON and OFF duringthe BIOS POST may never be called upon during later user operations.

Line-voltage monitoring steps 921-913 in software 800 (FIGS. 1A-1-1A-9)are also used to determine a specific user activity, namely,disconnecting power by removing connector 132 from battery pack 508BFIG. 13A). As soon as a 0-volt state is detected in step 938, MCU 102 Aand software 800 immediately issue a shutdown command to power converter122A. Precursors of this disconnect state include changes in line loadwhich are identified with an Ohm value previously identified as LL⁶. Ohmvalue LL⁶ corresponds to powered device 508C being turned OFF. If theanswer to software test in step 945 is FALSE (NO), software 800 commandspower conventer 122A in FIG. 13A to shut down.

Although the description above contains many specificities, these shouldnot be construed as limiting the scope of the invention, but as merelyproviding illustrations of some of the presently-preferred embodimentsof this invention. The scope of the invention should be determined bythe appended claims and their legal equivalents, rather than by theexamples given.

1. A system for selecting and applying a proper operating voltage for apreviously undetermined battery-powered device, comprising: means forsampling battery voltage of the previously undetermined batteryassociated with said powered device, to produce a sampled batteryvoltage; means for providing a reference voltage; means for comparingsaid sampled battery voltage and said reference voltage; means foradjusting said reference voltage and selecting a value of said referencevoltage that most closely matches said sampled battery voltage; andmeans for powering said powered device from a power source having anoutput voltage equal to said selected value of said reference voltage inthe absence of said battery being connected to said powered device. 2.The system as claimed in claim 1, comprising: means for providing avisual indication signifying that said sampled battery voltage and saidadjusted reference voltage are most closely matched.
 3. The system asclaimed in claim 2, comprising: means for choosing the next higher valueof reference voltage when said sampled battery voltage is in between twovalues of reference voltages, one value being below said sampled batteryvoltage and one value being above said sampled battery voltage.
 4. Thesystem as claimed in claim 1, comprising: means for protecting saidpower source from being inadvertently connected to said battery.
 5. Anapparatus for applying a power signal to previously undeterminedbattery-powered device, comprising: a transportable power-conversionmodule having two sets of at least two conductors each, the first setterminating at a source of power, and the second set terminating at aconnector interface interposed at an I/O port of said device forselectively accessing said device and said battery, said module furtherincluding: a processor/controller for executing program instructions foracquiring information from the previously undetermined battery as thebasis for computing a reference voltage for adjusting an output of aconfigurable regulator; a user-manipulable selector also for adjustingsaid regulator to a voltage value; a visual indicator for prompting auser as to whether a selected value is valid or invalid, based on theprocessor/controller comparing each selected value to the referencevoltage value; further program instructions for transferring adjustedvoltage information from a local non-volatile memory area to anaccessible non-volatile memory area associated with the device; the userhaving selected a valid voltage value, said processor/controllerprovides a distinguishable prompt to said user, configures saidregulator to output a power signal, and writes voltage value informationto said memory area of the device, whereby the power signal is appliedto the now-determined device, and later retrieval of information aboutthe power signal from memory associated with said device eliminatesfuture user manipulation of the selector.
 6. The apparatus of claim 5,further including a second connector located at the module-terminus ofsaid second set of conductors for detaching said conductors from themodule as a removable power cord, said memory area being electricallycoupled to the conductors either at said connector interface, or at thesecond connector; said processor/controller writes said adjusted voltagevalue to the memory by varying power signals output from said regulatoraccording to a format compatible with the memory, and by the user laterreattaching the now-configured power cord to the apparatus, saidprocessor retrieves the previously stored voltage value from the memoryat the second connector, compares the value to voltage values previouslystored in said local non- volatile memory, then configures the output ofsaid regulator.
 7. The apparatus of claim 6, wherein said connectorinterface is also electro-mechanically compatible with a pre-existingpower-input jack of the device.
 8. The apparatus of claim 5, whereinsaid processor/controller writes said adjusted voltage value to anaccessible non-volatile memory area at the device, then later retrievesthe voltage value from the device's memory when the user reattaches saidmodule to said device and, after comparing the retrieved value to thosepreviously stored in the local memory, said processor/controllerconfigures the output of said regulator.
 9. The apparatus of claim 8,wherein said non-volatile memory area is located in the power-inputcircuit of the device, so that reattaching said device to the apparatusat its power-input jack provides said processor/controller access to thedevice's memory area by applying a predetermined power signal from theregulator to the memory, thereby eliminating the need to turn on thedevice in order to access the memory.
 10. The apparatus of claim 8,further including a modulator/demodulator at both the apparatus and thedevice for transferring voltage value information by theprocessor/controller modulating said predetermined power signal alongtwo conductors.
 11. The apparatus of claim 8, further including adedicated data I/O connector located on the external housing of theapparatus for mating to a compatible connector located on an accessibleexternal surface of the device, thereby eliminating data-specificconductor-cables.
 12. The apparatus of claim 5, further includingwireless communications for transferring power-related informationbetween the memory areas at said apparatus and at said device.
 13. Theapparatus of claim 5, wherein the memory area is in the device at alocation accessible to the apparatus via the I/O port, and the apparatusfurther includes program instructions for, upon the user reattaching theapparatus to the I/O port, causing the processor/controller to retrievefrom the memory the previously-stored voltage value as the basis forthen configuring the output voltage of the regulator, therebyeliminating any user manipulation.
 14. The apparatus of claim 5, furtherincluding a spring-driven rotating reel onto which said power cord isretracted and stowed; a latching mechanism that prevents the extendedcord from inadvertently retracting while in use, the unlatching of whichis by the user applying a slight over-extension motion to the alreadyextended cord, then releasing said cord; a receiving housing forcapturing said connector plug so that the plug still remains accessibleto the user when the cord is in its fully retracted configuration. 15.The apparatus of claim 5, wherein said user-manipulable selector is apositionable dial upon which an indicia of a multiplicity of selectablevoltage values is displayed.
 16. The apparatus of claim 5, wherein saiduser-manipulable selector is a screen displaying an image that shows thevoltage value that the user has selected by manipulating a data-inputdevice.
 17. An apparatus for applying a power signal to abattery-powered device, comprising: a module as a battery enclosure of adimensional size and shape to fit within an existing battery compartmentof said device; a connector interface located along a suitable exteriorsurface of the enclosure so as to mate with an existing interface in thebattery compartment when the enclosure is installed into the batterycompartment; a connector receptacle exposed along an accessible face ofthe installed enclosure at which a user connects a mateable plug that iselectrically coupled at the terminus of at least two conductors directedto a power source; a processor for executing program instructions; amemory area for storing power-related information; an A/D converteraccessible to said processor capable of receiving a wide range of inputpower signals from either AC or DC power sources; a first regulator forconverting input AC power signals to a DC signal that is compatible withthe anticipated power-input requirements of the device; a secondregulator for converting input DC power signals to an output signal thatis compatible with said power-input requirements, and at least oneenergy storage element as a source of power for said device and internalcircuitry of the apparatus.
 18. An apparatus for applying a power signalto a previously undetermined battery-powered device, comprising: atransportable intermediate module for interconnecting between saiddevice and an AC/DC or DC/DC power-conversion peripheral that requires auser to select from a multiplicity of available voltages a valid outputvoltage for adjusting the power signal to the device; two sets of atleast two conductors each: the first set being for receiving powersignals from the peripheral, the conductors terminating at auser-accessible receptacle for accepting a power-output plug of theperipheral; the second set being for power output from the module, withconductors terminating at a connector interface interposed at an I/Oport of said device, said interface providing selective access to saiddevice and said battery; a processor/controller including programinstructions for acquiring power-related information from the battery asthe basis for computing a reference voltage value that is adjusted tooptimize said reference voltage value for each specific device, anow-optimized voltage value being written to an area of non-volatilememory; as the user makes selections, a visual indicator prompts theuser as to whether a selected value is valid or invalid, based on theprocessor/controller acquiring and comparing each distinct power signalreceived; said processor/controller also for controlling a switch whichprevents any invalid received voltage from passing through the module tothe device; said processor/controller provides a distinguishable promptto said user after the user having selected a valid voltage value, andthen allows the power signal from the peripheral to flow to the device.19. A system for applying a power signal to at least one of one or morepreviously undetermined battery-powered devices attached thereto,comprising: an embedded apparatus having an exposed connector receptacleas a port to which a user connects a device by attaching a compatibleconnector plug of a power cord, said cord comprised of at least twoconductors; at least two conductors for attaching said apparatus to apower source, and said apparatus further comprising: aprocessor/controller for executing program instructions; an A/Dconverter accessible to said processor/controller for acquiring powersignals from the attached device; a voltage regulator capable of havingits output power signals configured by said processor/controller; amemory area for storing power-related information; and an indicatorcapable of varying its visual characteristics, for prompting said user,whereby the user attaching the device to the power port causes theprocessor to acquire information about the device's power requirements,so as to configure the controllable regulator to output a power signalcompatible with said device, then activating the indicator to prompt theuser that the device is being powered.
 20. The system of claim 19,further including in the apparatus a spring-driven rotating reel ontowhich said power cord is retracted and stowed; a latching mechanism thatprevents the extended cord from inadvertently retracting while in use,the unlatching of which is by the user applying a slight over-extensionmotion to the already extended cord, then releasing said cord; areceiving housing for capturing said connector plug so that the plugstill remains accessible to the user when the cord is in its fullyretracted configuration.
 21. The system of claim 19, further includingin the apparatus wireless communications for transferring power-relatedinformation between the said apparatus and said device.
 22. The systemof claim 19, wherein said indicator is a display screen for promptingthe user.
 23. The system of claim 19, further including additionalprogram instructions for acquiring machine readable data that waspreviously written to a memory area located in said power cord so as tobe now accessible to the processor/controller, whereby retrieving fromthe memory at the power cord data for determining the power requirementsof the device enables the processor/controller to configure saidregulator to output the power signal to said device.